#Sauter Modulo 5 Controller Selection

Feature Spotlight: The Automated DDC Controller‐Selection Process

One of the hall-mark of the BMS-Automate sequence is the controller selection process. Selecting the right combination of DDC controllers and expansion modules that guarantees the least price is the goal here

In large projects—where you might have multiple master controllers and a variety of expansion modules with different I/O capacities—this can turn into a combinatorial puzzle.

Below is an example of how this was achieved with #Sauter Modulo 5 family of controllers. This has been and can be applied for other brands.

Understanding the Problem’s Complexity

• Multiple Master Controllers

-> EY‐AS525F005 and EY‐AS524F001 (Sauter “Modulo 5” series) each have their own onboard I/O.

-> AS525 can support up to 8 expansion modules. AS524 can only support 2 expansion modules.

->EY‐RC500F/502 (Sauter “EY‐RC500” family) have dedicated onboard I/O, but can add up to 8 SLC based modules.

-> EY‐RC504 is also part of the “EY‐RC500” family but lacks onboard I/O—it can instead support 16 SLC based modules.

• Varying Expansion Modules

-> EY‐IO530F001, EY‐IO531F001, etc. attach to the AS525/AS524 series. Each module offers different I/O mixes (some have purely digital inputs, others analog inputs, temperature inputs, or universal inputs etc.).

-> EY‐EM510F001, EY‐EM511F001, etc. Are the SLC based modules that attach to EY‐RC500/502/504 controllers. They similarly provide various combinations of analog and digital I/O.

• Constraints and Tradeoffs

-> Certain master controllers can only host a limited number of expansion modules (e.g., 2 for AS524).

-> Each module’s I/O type and capacity must align with the project’s point list (TI, AI, DI, AO, DO, etc.). Every point must fit somewhere in the system—while also avoiding an unnecessarily expensive combination.

-> There are different types of points provided by the modules or the controllers that serves dual purposes. For example a controller can provide a UI (accepts both digital and analog input), a DI/DO (that accepts digital input or digital output).

The core difficulty is that all permutations of master controllers plus expansions must be evaluated to guarantee there’s no overlooked, lower‐cost alternative.

Even small differences in point capacity or spares can affect whether you need an additional module or can downsize an existing one, each combination potentially saving or adding cost.

Integrated Into BMS_Automate

This automated selection is part of the larger BMS_Automate sequence, which handles a full range of BMS tasks—from generating point lists per DDC to final estimation.

When the point list per DDC is generated, the system automatically matches those points with the most suitable controllers:

1. Choose a Mode AS525/524 or EY‐RC500/EY‐RC504 (with expanded module support)
2. Enter Points The user (or the broader software sequence) inputs the number of required TIs, AIs, DIs, AOs, DOs, network points, etc.
3. Iterative Calculation The program iterates through all valid combinations: Checks which expansions each master can host. Ensures that total I/O capacity covers all points. Verifies no cheaper combination is missed in favor of a more expensive one.
4. Output Identifies the exact controller part numbers (for instance, EY‐AS525F005 plus four expansions of EY‐IO572F001). Ensures no oversizing if a smaller or fewer modules combination meets the requirements.

Manual Selection vs. Automation

Alongside the automated routine, there’s also a manual controller‐selection sheet where a user can enter I/O needs themselves and see which controllers and expansions might fit.

This is handy for quick checks or smaller jobs. However, for larger or more complex projects (with dozens of panels and thousands of points), BMS_Automate’s full iteration approach:

• Saves Time: No trial‐and‐error or guesswork.
• Prevents Overspending: The algorithm compares all options, so you don’t inadvertently oversize a panel.
• Guarantees Consistency: Every panel or site uses the same systematic logic.

Why It Matters

With the DDC Controller‐Selection feature, BMS engineers can trust that:

• All Requirements Are Met The capacity for TIs, AIs, DIs, AOs, DOs, and network points is satisfied.
• Spares Are Accounted for It factors in spare capacity targets to future‐proof your system.
• Least‐Cost Combination The iterative checking process ensures no combination is chosen if there’s a more cost‐effective solution offering the same functionality.

This tool goes beyond merely listing hardware: it smartly configures each BMS panel to minimize cost, handle spares, and fit the correct hardware expansions—a powerful advantage for both in‐house engineering teams and external contractors.

Conclusion

The controller‐selection feature in BMS_Automate tackles a complex optimization challenge, comparing every possible mix of master controllers and expansions to find the best fit.

It’s seamlessly integrated with point‐list generation, so every DDC is automatically assigned the right modules—all in seconds rather than days.

Whether you opt for AS525/524 modules or prefer the EY‐RC500/502/504 family, the process remains consistent, reliable, and budget‐friendly.

In short, this automated solution transforms a tedious, error‐prone stage of BMS design into a fast, systematic, and cost‐optimized routine—freeing your team to focus on delivering better building automation outcomes.