Maintaining precise temperature and humidity is essential in clean room environments, where product quality, process reliability, and regulatory compliance depend on stable environmental conditions. A manufacturing facility at Ballard Power Systems required a control solution to monitor and manage three independent clean rooms while providing operators with centralized visibility and secure, remote access.
With more than four decades of expertise, Ballard Power Systems develops and manufactures efficient, sustainable hydrogen fuel cell power systems for zero-emission applications across automotive, maritime, rail, and backup power industries.
Project Objectives
The facility required reliable communication between systems that used different industrial protocols. PoolPak dehumidifiers communicated using BACnet/IP, while the room control systems used Allen-Bradley Micro800 PLCs. A 2080sc-BAC BACnet Communications Plug-in Module was installed on the Micro800, allowing it to communicate as a BACnet IP server.
The challenge was to create a seamless architecture that allowed operators to monitor and adjust critical environmental variables from a single interface while maintaining dependable communication across all devices.
Key project objectives included:
- Monitoring and controlling three PoolPak dehumidification units
- Maintaining temperature and humidity conditions within each clean room
- Controlling humidification equipment
- Managing outdoor air and supply air fan operation
- Monitoring outdoor air temperature (OAT) and supply air temperature (SAT)
- Providing a user-friendly interface for local and remote operation
The Solution
Christian Bourque, Sr. Controls Technologist at Ballard Power Systems, selected a solution built around a Contemporary Controls BASC-22DR BACnet controller, combined with Allen-Bradley Micro800 PLCs and PanelView 800 HMIs, to create an integrated Building Automation and Environmental Control System.
The BASC-22DR served as the system’s integration platform. This 22-point unitary controller supports BACnet/IP client/server operation and uses the license-free Sedona function block programming language.
The BASC-22DR leveraged Sedona network variable (NETV) components to function as a BACnet/IP client. This allowed the controller to initiate BACnet/IP communication without requiring a head-end system.
The BASC-22DR was configured to communicate with:
- Three PoolPak dehumidifiers via BACnet/IP
- Three Allen-Bradley Micro800 PLCs
- Environmental monitoring devices throughout the facility
Each clean room was equipped with dedicated wall-mounted temperature and humidity sensors connected directly to the PLC analog inputs. The PLCs performed local control functions including:
- Outdoor air fan control
- Supply air fan control
- Humidifier control
- Room environmental monitoring
Communication between the PLCs and the BASC-22DR was accomplished via a 2080sc-BAC, allowing the PLCs to function as BACnet/IP servers and support real-time data exchange between all control components.
A graphical interface was developed using PanelView 800 HMIs to provide intuitive operator interaction. An integrated VNC server enabled secure remote access and control, allowing authorized personnel to monitor room conditions and adjust operational setpoints without being on site.
The Results
The completed system delivered precise environmental control while reducing the complexity of managing multiple independent systems. It successfully integrated multiple HVAC and control technologies into a unified platform, providing:
- Centralized monitoring of all three clean rooms
- Real-time temperature and humidity visibility
- Remote adjustment of dehumidifier temperature and humidity setpoints
- Automated humidification control
- Reliable BACnet/IP-to-PLC interoperability
- Simplified operator access through a graphical HMI interface
- Improved operational efficiency through remote access
According to Bourque, the BASC-22DR played a critical role in bridging communication between the PoolPak dehumidifiers and the Micro800 PLC-based control system. Its ability to simultaneously support BACnet/IP communications and custom integration strategies allowed the project team to create a flexible, scalable architecture without the need for additional protocol conversion hardware.
The use of NETV components simplified configuration, enabling rapid deployment and commissioning while maintaining the reliability required for clean room applications.
“Diego Mateo from Contemporary Controls’ Technical Support instilled confidence that this project would come together as expected, and it met all expectations,” said Bourque. “The support and expertise he provided throughout the project helped ensure a successful deployment.”
The result is a robust environmental control system that delivers dependable performance, streamlined operation, and the flexibility required for future expansion.
Products and Protocols Used
- Modbus TCP Communications
- Contemporary Controls BASC-22DR BAScontrol Controller
- PoolPak Dehumidification Units
- Allen-Bradley Micro800 PLCs with a 2080sc-BAC Communications Module
- Allen-Bradley PanelView 800 HMIs
- BACnet/IP Communications
