1. The "DCS in a Box" SIMATIC PCS 7 BOX
Welcome to the Presentation of SIMATIC PCS 7 BOX, the “DCS in a Box”
6/2004

2. Agenda Introduction & Overview System Architectures
More Details on the Industrial PC
More Details on the Controller
Packaging and Bundling
Summary
Questions & Answers
6/2004

3. Trends in Process Automation…
Controller
Controller
Controller PC
Intelligent Field Devices PC
1990
2000
2010
Market studies indicate that are several important trends that are driving the direction of Process Automation Today. In the area of system Architectures there is an in increasing acceptance rate of PC-based process automation solutions. Additionally as the business climate changes customers are looking for truly distributed architectures to improve their production and operation efficiencies.
PC-based Process Automation Solutions are becoming more prevalent
Decentral today
Distributed tomorrow
Central yesterday
Distributed Architectures are required to meet tomorrow’s business needs
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4. Trends in Process Automation...
Market Studies of DCS System Architecture by ARC
Studies of the Process Automation marketplace by ARC, a leading industry consultant group, have shown a large increase in the number of “Small” systems being installed by customers. “Small” systems are defined in the table above as consisting of 1 or 2 Operator Consoles, along with 1 or 2 Controllers in a system of less than 900 real I/O. This trend is probably fueled by the capital expenditure practices of companies in today’s economy, where it is extremely difficult (and risky) to get large projects approved.
Number of “Small” Plants (x 1000)
According to ARC, business drivers are pushing customers to install “Small” systems
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5. Trends in Process Automation...
Hardware Cost per Small Plant (x $1000)
These same studies also show that customers expect a continuous decrease in the cost of the hardware employed in their Small process Automation Systems.
The market demands a continuous reduction in the cost of process automation system hardware
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6. To respond to these business drivers, Siemens has introduced PCS 7 BOX – The “DCS in a Box”
Included in the “Box”
Operator Interface
Hardened Controller
Fieldbus Connections
Engineering Software
MS-SQL-based Historian
Field Device Management
Batch Manager
Operator Interface
Engineering Tools
Box PC
PROFIBUS
PCS 7 Box is based on a compact industrial PC with a small footprint and low cost. Integrated inside are all of the functional components that make up a DCS:
Operator Interface Software
A Hardened Controller in the form factor of a PC card installed in the PCI Slot of the PC – this is called a “Slot CPU”
Fieldbus Connections (2 X PROFIBUS DP) built into the hardened controller allowing users to connect up to remote I/O systems or “smart” field devices such as Analyzers, Transmitters, Valve Positioners, Motor Control Centers and VFDs\
Engineering Software to allow configuration of Control and HMI Strategies
A MS-SQL based Historian for storing alarms, events, operator actions and process data
Optional Field Device Management Tool (Process Device Manager) for configuration of smart field devices (HART, PROFIBUS DP / PA) all from a central location
Optional Batch Management Software
PCS 7 BOX is the first PC-based, integrated, DCS controller on the market. It provides the ideal solution to capitalize on the trends in automation
6/2004

7. Potential Advantages of a PC-based Solution
Simple connection to the office world using Industrial Ethernet and standard mechanisms such as OPC
Low cost, integrated solution on a single hardware platform
Simple connection to the web
Simple integration of custom application software (e.g. C++ programs or Visual Basic)
Use of standard MS Office Tools (eg. Excel)
Uses widely used, standard Microsoft Windows Operating Systems
High Computing Capacity
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8. Key Design Considerations for PC-based control in Process Industries
Uses IPCs with MTBFs of > ºC during 24/7 operation
Uses same software as PCS 7 (LAD, FBD, SFC,CFC, SCL, SCL)
Slot CPU operates independently of the operating system
Slot CPU continues to operate in the event of a PC failure
PCS 7 BOX Design
High failure rate of PC hardware
Complex Control Software
Insufficient real-time performance of the operating system
Dependence on constantly changing (and sometimes unstable) Windows Operating systems
To achieve the advantages and benefits of PC-based control required us to overcome some key characteristics of typical PC-based control systems of the past. These include:
The high failure rate of PC hardware…How many people have ever had some component of their PC fail (like the hard drive) ?
Complex Control Software – Previous PC-based control products used unique and proprietary configuration tools and languages
Insufficient real-time performance of the operating system – real time control using an open operating system like Windows send shutters down the spine of many folks
Dependence on constantly changing and sometimes unstable Windows Operating Systems…Has any one ever gotten the “blue screen of death” on their PC or had a time when the PC locked up and needed to be rebooted to recover ?
These Considerations were overcome during the design of PCS 7 Box…
PCS 7 Box uses an Industrial PC with a Mean Time Between Failures (MTBF) of greater than 20 years when operated continuously (24/7) at an elevated temperature of 45 Degrees C..Imagine having a PC failure only once in 20 years ?
The Engineering environment uses an identical toolset as PCS 7. The well-known configuration languages of the IEC standard such as Ladder Logic, Function Block, Sequntial Function Chart, Continuous Function Chart, Structured Control Language etc are provided standard to allow you to quickly and easily configuration your regulatory control applications and your discrete control applications.
The Slot CPU operates independently of the Microsoft Operating system so its performance is unaffected. It even has its own source of power so that it will continue to control your plant if the PC need to be shutdown or rebooted.
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9. Physical Dimensions of PCS 7 BOX
This photo of a prototype system gives you a feel for the physical size of the PCS 7 Box Unit…pretty small and compact (much smaller than a conventional PC)
Remember that this 12 x 12 x 4 inch PC includes the controller, ethernet cards and ports for connecting to PROFIBUS
PCS 7 BOX: approx 12” x 12” x 4”, 14 lbs
Small footprint and light weight means it is easy to mount in the field
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10. PCS 7 BOX is offered in two flavors
Runtime Only
Operator Station
AS / OS
6ES7650-2HB06-0YX0 +
Controller
Functionality
Software
PCS 7 Box has two different models. The first is a unit that is used only for Operation, Monitoring and Control, but does not contain any Engineering Capability. The second model adds Engineering Capability on top of Operation, Monitoring and Control.
In both cases the PCs come preinstalled with MS Windows 2000 and PCS 7 Software
Runtime
Configuration
AS / OS / ES
Operator Station
Engineering Station +
Controller
6ES7650-2HA06-0YX0
Functionality
Software
Software is Preinstalled on the PC
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11. PCS 7 BOX shares common hardware and software with PCS 7, providing an unprecedented level of scalability
Pilot
Plant
Manufacturing plant
Multiple plants at a
manufacturing site
One of PCS 7’s Strengths and TRUE differentiators is in its scalability (from 100s of I/O to 100,000 I/O). Since PCS 7 BOX shares common hardware and software with PCS 7, it is easy to reuse its hardware and engineering elements as you expand or modify your plant over time. For instance it would be very easy to scale up from a pilot plant application to a full production environment.
PCS 7 Box is scalable and upgradable. The standard offering comes with a license for 250 Process Objects, where a process object is an element like a motor, single loop controller or discrete block valve…basically any item from a P&ID that will have a faceplate in the HMI. It is upgradable (via Powerpacks) to 2000 Process Objects which would allow it to be used with much larger systems handling 1000’s of I/O points.
The license for PCS 7 Box is portable and could be reused in a TRUE PCS 7 Client / Server Architecture as well
Scalable
from PCS 7 BOX...
...to a distributed system with client/ server architecture (~ 100,000 I/O)
Scalability in PCS 7 means that you can reuse hardware and engineering elements as you expand or modify your plant
6/2004

12. Three Possible System Architectures
Application
Standalone Operator Station / Controller
Standalone Operator Station / Controller with Integrated Engineering
Local Operator Station / Controller with connection to PCS 7 system
Economical & Powerful Single Station with DCS-style functionality
Single Station with DCS-style functionality and Engineering Tools
Unit Controller (for Skid Mounted Equipment)
Controller-to-Controller Communication
Engineered from Central Workstation which is also used for the DCS 1.
PCS 7 BOX can be utilized in several different architectures which opens up many possible applications.
Firstly in can be utilized as a standalone Operator Station plus Controller. This offers a very economical and powerful single station with DCS-style functionality at the operator interface. In this architecture, all configuration changes would be made from an External (Remote) engineering station that would be connected temporarily for the purposes of engineering. This is a good architecture for OEMs that want to deliver a powerful system that cannot be easily modified by the end user. It would allow 100s of systems to be created and serviced by a single Engineering Station
The second architecture option is to utilize PCS 7 Box as a combination Operator Station, Controller and Engineering Station. This provides full DCS style functionality and Engineering Tools to allow configuration to be done locally on the PC
The third architecture allows the PCS 7 Box to be used as a type of unit controller in a networked PCS 7 System Architecture. Thus PCS 7 Box would be a self-contained unit for operation & control of a specific piece of equipment, but would be networked into a PCS 7 Client / Server architecture. In this case the configuration would be done from the same central engineering workstation that is used to configure the PCS 7 system, making it easy to reuse engineering libraries and institute configuration management between the DCS and its support equipment. 2. 3.
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13. Standalone Operator Station / Controller
As we said the first architecture is the use of PCS 7 Box in a Standalone Operator Station / Controller. In this architecture a remote (floating) engineering station must be used to load the configuration (controller and HMI) and to make incremental engineering changes. The Onboard Ethernet Card is used to connect PCS 7 Box to the External Engineering station. It is through this Ethernet Connection that a user would download the programs to both the controller (Slot CPU) and to the Operator Station (HMI).
To configure smart field devices connected to the integrated PROFIBUS DP Port, A CP 5611 card would be required in the external engineering station. This card would allow the Process Device Manager (PDM) tool loaded on the external engineering station to configure, troubleshoot and commission smart devices.
The following are Background Notes for the Presenter:
Restrictions/Constraints in this Architecture:
Time synchronization between the CPU and the OS can be implemented only using WinAC time synch from the PC Clock – Does not support connection of an external time synch clock
The PROFIBUS DP/MPI port is fully functional but its capacity is limited. It is recommended to connect only I/O stations to this interface which do not require configuration through PDM. The dedicated PROFIBUS port should be used for this purpose.
The Hardware configuration cannot be modified online in this version (CiR is not available) – This functionality will be added to a future release of WinAC
Download Control, HMI Configuration
Configuration from a Remote (floating) Engineering Station
6/2004

14. Standalone Operator Station / Controller with Integrated Engineering
The second architecture consists of PCS 7 Box in a Standalone Operator Station / Controlle with Integrated Engineering Capability. In this architecture the integrated engineering station is used to load the configuration (controller and HMI) and to make incremental engineering changes.
To configure smart field devices connected to the integrated PROFIBUS DP Port, the onboard CP 5611 card can is used. This card would allow the Process Device Manager (PDM) tool loaded on BOX PC to configure, troubleshoot and commission smart devices.
The following are Background Notes for the Presenter:
Note that a separate license must be purchased to activate PDM (it is already installed on the PC)
In this configuration PDM Routing is not possible. PDM operates as a direct connection to the Integrated PROFIBUS DP port, which means that the PDM Lifelist capability works (auto recognition of devices added to PROFIBUS)
Restrictions/Constraints in this Architecture:
Time synchronization between the CPU and the OS can be implemented only using WinAC time synch from the PC Clock – Does not support connection of an external time synch clock
The PROFIBUS DP/MPI port is fully functional but its capacity is limited. It is recommended to connect only I/O stations to this interface which do not require configuration through PDM. The dedicated PROFIBUS port should be used for this purpose.
The Hardware configuration cannot be modified online in this version (CiR is not available) – This functionality will be added to a future release of WinAC
Configuration Changes to the OS cannot be loaded while online
Configuration is done using the Integrated Engineering capability
6/2004

15. Local Operator Station / Controller with connection to PCS 7 Network
In the third architecture PCS 7 Box is integrated in a PCS 7 network and also functions as an Operator Station / Controller. In this architecture a remote (floating) engineering station must be used to load the configuration (controller and HMI) and to make incremental engineering changes. The Onboard Ethernet Card is used to connect PCS 7 Box to the External Engineering station. It is through this Ethernet Connection (on the System Bus) that a user would download the program to the controller (Slot CPU).
The System Bus connection enabled by the onboard Ethernet Card also allows PCS 7 Box to communicate with Automation Stations from the PCS 7 Network (via Controller-to-Controller Communication) or to OS Servers from the PCS 7 Network (to allow data from the PCS 7 Box Controller to be displayed within the OS Clients of the PCS 7 Network.
An optional second ethernet card (in the form of a CP 1512 PCMCIA card) can also be installed in PCS 7 Box. It is through this Ethernet Connection (on the Terminal Bus) that a user would download the program from the external engineering station to the Operator Station (HMI).
To configure smart field devices connected to the integrated PROFIBUS DP Port, the onboard CP 5611 card can is used. This card would allow the Process Device Manager (PDM) tool loaded on BOX PC to configure, troubleshoot and commission smart devices.
The following are Background Notes for the Presenter:
Restrictions/Constraints in this Architecture:
Communication between the OS in the SIMATIC Box PC and an OS Server is currently not planned
Operation 7 is currently not planned
The PROFIBUS DP/MPI port is fully functional but its capacity is limited. It is recommended to connect only I/O stations to this interface which do not require configuration through PDM. The dedicated PROFIBUS port should be used for this purpose.
The Hardware configuration cannot be modified online in this version (CiR is not available) – This functionality will be added to a future release of WinAC
Single, Central Engr Station can be used to configure PCS 7 Box and the PCS 7 Network
6/2004

16. More Details on the PC
6/2004

17. SIMATIC Box PC 620 – high performance in a small form factor
The following are Background Notes for the Presenter:
Ambient Air Temperature During Operation: 5 to 45 Degrees C
Humidity: 5-80% at 25 Degrees C
Degree of Protection IP 20
Vibration and Shock Resistant
High Immunity to EMC
Size = 11.7 x 11.9 x 4.0 inches
Weight = 14.2 lbs approximately (including CPU)
Designed for use in Industrial Environments
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18. SIMATIC Box PC 620 – expandable to meet your needs
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19. SIMATIC Box PC 620 Technical specifications
Subject to technical changes/improvements without prior notice.
Basic specifications
CPU
Intel Pentium III 1.26GHz, 133 MHz FSB
RAM
1GB SDRAM-133 (including graphic memory)
Hard Drive
80 GB HDD EIDE
Diskette Drive
3.5”, 1.44 MB
DVD-ROM / CD-RW
Combo Drive 8 / 8 / 24 Speed
Ethernet
Integrated (Onboard) Ethernet Port 10/100 Mbs (RJ45)
PROFIBUS
CP 5611 Compatible Onboard
USB
2 connections (high current)
Vacant slots for expansion
1 Card Bus for PCMCIA Type III PC Card
(Typically used for Optional Ethernet CP 1512 Card)
Graphics
UXGA LCD controller on AGP bus; 1280 x 85Hz, For connection of External Monitors and LCD Displays
Operating system
Microsoft Windows 2000 Professional
Power supply
24V DC
Serial Port
RS 232: 9-pin: COM2
Standard Ports
Mouse, Keyboard and Printer
This Slide shows some of the Detailed technical Specifications for the Box PC 620. In Particular I would call your attention to the following important characteristics:
1 GB RAM is installed standard to provide power to use the station effectively for engineering and for operations and monitoring
An onboard Ethernet Card is provided to allow the PC to be connected to a floating engineering station or to allow it to communicate over the System Bus to other CPUs in a PCS 7 Architecture (Controller to Controller Communication)
An onboard PROFIBUS CP 5611 Compatible Interface is provided to allow the user to configure and maintain smart field devices using PDM (the PROFIBUS Device Manager). Through this card the user can configure PROFIBUS DP and PA devices and can use the pwoerful lifelsit (auto recognition) capability of PDM
System can be expanded to add a second Ethernet Card (CP 1512) which would allow PCS 7 Box to be connected to the Terminal Bus of a PCS 7 Client / Server Architecture
The Graphics Card allows connection of External Monitors and LCD Displays directly to the PC
6/2004

20. SIMATIC WinAC Slot CPU WinAC Slot CPU 416-2DP
Same performance as an S7-400 Controller (416-2)
Controller operation is independent of PC and Windows 2000 (Continues to control through reboot of the PC)
Built-in battery backup
MPI and PROFIBUS DP interfaces onboard
Built in 24 V power supply extension board allows controller to be powered separately from the PC
The following are Background Notes for the Presenter:
WinAC Slot 416-2DP (1.6 MB memory for code and 1.6 MB memory for data)
Has 1 PROFIBUS DP Interface and 1 MPI/DP Interface
With power supply extension board the Slot CPU occupies 2 PCI slots in the PC
Backup Battery is built in and is provided standard
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21. SIMATIC WinAC Slot CPU 2MB Memory Expansion Card is provided standard
Memory Card
(RAM/Flash)
MPI/DP Interface
(external)
The following are Background Notes for the Presenter:
WinAC Slot 416-2DP (1.6 MB memory for code and 1.6 MB memory for data)
Load Memory = 256 Kbytes + 2 Mbyte Built-in Memory Card
Has 1 PROFIBUS DP Interface and 1 MPI/DP Interface
With power supply extension board the Slot CPU occupies 2 PCI slots in the PC
Backup Battery is built in and is provided standard
LED Stop/Run
Connector for backup battery
Profibus-DP
Interface
External Power Supply 24V
2MB Memory Expansion Card is provided standard
Integrated Profibus Interface allows connection to standard SIMATIC ET 200 I/O Subsystems
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22. CPU Panel Status and Error Indicators of the CPU Buffer Battery
Status LED
FW Update ...
Mode Selection
CPU Status and Error Indication can be viewed from the Monitor
Provides some level of diagnostics and indication as a regular S7-400 CPU
Firmware can be updated over the network without having to remove the CPU card
Memory Reset
Status and Error
Indicators of the CPU
6/2004

23. PCS 7 BOX – Bill of Materials for Operator Station / Controller
Runtime Only
Operator Station
AS / OS
6ES7650-2HB06-0YX0 +
Controller
Functionality
Software
Also note than an OPC Server / Client are included at no extra charge (with no additional licensing fees)
The following are Background Notes for the Presenter:
US List Price is approximately $ 13,000 not including I/O
Included Standard “Out of the Box”
SIMATIC Box PC 620, 24 VDC
WinAC Slot CPU 416 V3.4 (built-in)
Expansion Memory Card, 2 MB (built-in)
WinAC Power Supply Extension Board (built-in)
Backup Battery (built-in)
SIMATIC PCS 7 OS Single Station runtime license (250 PO / RT 8K)
OPC Client / OPC Server
SIMATIC PCS 7 AS Library runtime license
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24. Included Standard “Out of the Box”
PCS 7 BOX – Bill of Materials for Operator Station / Controller with Integrated Engineering
Runtime
Configuration
AS / OS / ES
Operator Station
Engineering Station +
Controller
6ES7650-2HA06-0YX0
Functionality
Software
Also note than an OPC Server / Client are included at no extra charge (with no additional licensing fees)
The following are Background Notes for the Presenter:
US List Price is approximately $ 20,000 not including I/O
Included Standard “Out of the Box”
SIMATIC Box PC 620, 24 VDC
WinAC Slot CPU 416 V3.4 (built-in)
Expansion Memory Card, 2 MB (built-in)
WinAC Power Supply Extension Board (built-in)
Backup Battery (built-in)
SIMATIC PCS 7 AS and OS Engineering / runtime license (250 PO / RC 8K)
OPC Client / OPC Server
SIMATIC PCS 7 AS Library runtime license
6/2004

25. Scalability & Upgradability of PCS 7 BOX
Small Scale
Large Scale
Operator Station
250 Process Objects
2000 Process Objects +
Controller
The two models of PCS 7 Box are scalable and upgradable. The standard offering comes with a license for 250 Process Objects, where a process object is an element like a motor, single loop controller or discrete block valve…basically any item from a P&ID that will have a faceplate in the HMI. It is upgradable (via Powerpacks) to 2000 Process Objects which would allow it to be used with much larger systems handling 1000’s of I/O points.
The license for PCS 7 Box is portable and could be reused in a TRUE PCS 7 Client / Server Architecture as well
Operator Station +
Controller
250 Process Objects
2000 Process Objects +
Engineering Station
Standard Package (Default)
PID Controller
Motor
Process Object:
Any control element that has a corresponding faceplate in the HMI
Analog Indicator
6/2004

26. SIMATIC PCS 7 Box Optional Accessories
Accessories (not included in the scope of supply)
CP 1512 to connect to the SIMATIC PCS 7 Terminal Bus
6GK1151-2AA00
PCS 7 Engineering Powerpack V6.0 (Upgrade from PO 250 / RC 8K to PO 2000 / RC 64K)
6ES7658-5AB06-0YD0
PCS 7 OS Software Single Station Powerpack V6.0 (Upgrade from PO 250 / RT 8K to PO 2000 / RT 64K)
6ES7658-2AB06-0YD0
SIMATIC PDM 128 Tags
6ES7658-3PX05-0YC0
Keyboard
Choose from catalog ST 80 or 3rd party
Monitor
24 VDC Industrial Power Supply
Recommendation is SITOP from CA01 Catalog
I/O Modules
Order from Catalog ST PCS 7 based on project requirements
The following are Background Notes for the Presenter:
For small Batch applications it is possible to have the Batch Manager integrated in PCS 7 Box. The application must be approved by Product Management in Headquarters.
6/2004

27. PCS 7 Box “Going Where No DCS Has Gone Before”
Benefits
Provides DCS functionality in applications where it was previously too expensive or too large
Reduces Integration Costs – by making it easier to integrate secondary processes and DCS applications
Compact Footprint
Supports applications requiring FDA Validation
Scalable and Expandable
Allows standardization of Control & HMI Elements between Skids and DCS
Controller powered independently of PC…Controller is not part of PC
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28. PCS 7 Box “Going Where No DCS Has Gone Before”
Applications
OEMs to the Process Industry
Skid Vendors (“Smart Skids)
Secondary Processing
Pilot Plant Applications
Stand-Alone or Networked Architectures
Controller powered independently of PC…Controller is not part of PC
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29. Questions ? Thanks for Listening !
6/2004