The Kennedy Complex Control System (KCCS) is a replacement for KSC’s Complex Control System (CCS), which controls and monitors power, HVAC, potable water and wastewater, compressed gas distribution, and other facility- and utility-related systems throughout KSC. The existing CCS was derived from NASA’s Launch Processing System and is based on custom hardware developed in the 1970’s that can no longer be maintained except by cannibalization. KCCS is a powerful, highly robust, and flexible system based entirely on commercial off-the-shelf (COTS) hardware and software and offers significant cost savings to NASA over attempting to maintain the old system.

When complete, KCCS will have replaced CCS in approximately 30 facilities throughout KSC and transferred approximately 11,000 measurement control points with SquareD/Modicon programmable logic controllers (PLC’s) and PC-based servers. These PLC’s communicate via a redundant ATX Ethernet to servers located at the Launch Control Center. These servers run redundant Supervisory Control and Data Acquisition (SCADA) software, input/output servers, data trending servers, alarm servers, and report generators. The result is a system that is extremely robust and tolerates network failures, software glitches, and computer hardware failures without losing data.

The COTS-based KCCS was also selected for its ability to communicate with newer technology sensors and “smart” devices using a large variety of communication formats including Ethernet, LONWORKS, MODBUS, MODBUS/TCP, PROFIBUS, DEVICENET, SERIPLEX, and other common industrial field buses. The system can also communicate with equipment made by Andover Controls. In addition, the system can accept existing commercial instrumentation outputs such as analog voltages, current loop, contact closure, and other standard quantities.

Currently there are approximately 10 active installations of KCCS.

Key accomplishments:

• 1998: Design trade study and requirements definition.
• 1999: Market survey and hardware selection.
• 2000: Activation of first installation.
• 2001: Resolution of issues with SCADA and redundant trend servers.

Key milestones:

• 2002: Design/installation and activation of numerous sites.
• 2003: Conversion of measurements for launch pad fire sprinkler and water deluge systems. Activation of all sites.
• 2004: Facility modifications to Launch Control Center.

Contact: P.A. Mogan (Paul.Mogan-1@ksc.nasa.gov), YA-E2, (321) 867-8574
Participating Organizations: PH-J (C.E. Jenkins, J.R. Rymkos, C.J. Iannello, Z.M. Ruedele, W.R. Martin, and J.R. Lorch), United Space Alliance (L.A. Messemer and L.J. Boyd), Lockheed Martin Space Operations (B.J. Birnhak), and Space Gateway Support (L.W. Kiel and P. Kroning)