1 Automation and Drives "DCS in a Box" SIMATIC PCS 7 BOX 6/2004 SIMATIC PCS 7 BOX The "DCS in a Box"

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Automation and Drives

"DCS in a Box"SIMATIC

PCS 7 BOX

SIMATIC PCS 7 BOXSIMATIC PCS 7 BOXSIMATIC PCS 7 BOXSIMATIC PCS 7 BOX

The The "DCS in a"DCS in a Box Box""The The "DCS in a"DCS in a Box Box""

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PCS 7 BOX

Trends in Process Automation...

According to ARC, business drivers are pushing customers to install “Small” systems

According to ARC, business drivers are pushing customers to install “Small” systems

10

10.5

11

11.5

12

12.5

13

13.5

2000 2001 2002 2003 2004 2005

Small Medium LargeHMI/ES Stations 1-2 3-8 >8Controllers 1-2 3-8 >8Analog I/O's 0-299 300-799 800+Digital I/O's 0-599 600-1499 1500+CAGR Number of Systems 3.3% 2.3% 0.6%CAGR Average Selling Price -9.5% -10.8% 0.3%Numbers in 2001 11600 8900 2000

Market Studies of DCS System Architecture by ARCMarket Studies of DCS System Architecture by ARC

Number of “Small” Plants (x 1000)Number of “Small” Plants (x 1000)

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PCS 7 BOX

Trends in Process Automation...

The market demands a continuous reduction in the cost of process automation system

hardware

The market demands a continuous reduction in the cost of process automation system

hardware

0

5

10

15

20

25

30

2000 2001 2002 2003 2004 2005

Hardware Cost per Small Plant (x $1000)Hardware Cost per Small Plant (x $1000)

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PCS 7 BOX

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 InterfaceEngineering Tools

PROFIBUS

Box PC

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

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

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PCS 7 BOX

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

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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PCS 7 BOX

Key Design Considerations for PC-based control in Process Industries

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

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

ConsiderationsConsiderations

Uses IPCs with MTBFs of > 20 years @ 45 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

Uses IPCs with MTBFs of > 20 years @ 45 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 DesignPCS 7 BOX Design

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PCS 7 BOX

Physical Dimensions of PCS 7 BOX

PCS 7 BOX: approx 12” x 12” x 4”, 14 lbs

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

Small footprint and light weight means it is easy to mount in the field

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PCS 7 BOX

PCS 7 BOX is offered in two flavors

Software is Preinstalled on the PC

Software is Preinstalled on the PC

Runtime Only

Runtime OnlyOperator

StationOperator Station

AS / OSAS / OS

6ES7650-2HB06-0YX0

++

ControllerController

FunctionalityFunctionality SoftwareSoftware

Runtime Runtime Configuration

Configuration

AS / OS / ESAS / OS / ES

Operator Station

Operator Station

Engineering Station

Engineering Station

++

++ControllerController

6ES7650-2HA06-0YX0


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PCS 7 BOX

Scalablefrom PCS 7 BOX...

PCS 7 BOX shares common hardware and software with PCS 7, providing an unprecedented level of scalability

...to a distributed system with client/ server architecture (~ 100,000 I/O)

PilotPlant

Manufacturing plant

Multiple plants at a manufacturing site

Scalability in PCS 7 means that you can reuse hardware and engineering elements as you

expand or modify your plant

Scalability in PCS 7 means that you can reuse hardware and engineering elements as you

expand or modify your plant

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PCS 7 BOX

Three Possible System Architectures

Standalone Operator Station / Controller

Standalone Operator Station / Controller with Integrated Engineering

Local Operator Station / Controller with connection to PCS 7 system



Local Operator Station / Controller with connection to PCS 7 system

ArchitectureArchitecture

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

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

ApplicationApplication

1. 1.

2. 2.

3. 3.

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PCS 7 BOX


Configuration from a Remote (floating) Engineering StationConfiguration from a Remote (floating) Engineering Station

Download Control, HMI

Configuration

Download Control, HMI

Configuration

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PCS 7 BOX


Configuration is done using the Integrated Engineering

capability

Configuration is done using the Integrated Engineering

capability

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PCS 7 BOX

Local Operator Station / Controller with connection to PCS 7 Network

Single, Central Engr Station can

be used to configure PCS 7 Box and the PCS

7 Network

Single, Central Engr Station can

be used to configure PCS 7 Box and the PCS

7 Network

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PCS 7 BOX

More Details on the PC

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PCS 7 BOX

SIMATIC Box PC 620 – high performance in a small form factor

Designed for use in Industrial Environments

Designed for use in Industrial Environments

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PCS 7 BOX

SIMATIC Box PC 620 – expandable to meet your needs

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PCS 7 BOX

SIMATIC Box PC 620Technical specifications

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 1024 @ 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

Subject to technical changes/improvements without prior notice.

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PCS 7 BOX

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

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PCS 7 BOX

SIMATIC WinAC Slot CPU

2MB Memory Expansion Card is provided standard Integrated Profibus Interface allows connection to standard

SIMATIC ET 200 I/O Subsystems

Profibus-DPInterface External Power

Supply 24V

Memory Card(RAM/Flash)

Connector forbackup battery

MPI/DP Interface(external)

LED Stop/Run

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PCS 7 BOX

CPU Panel

Buffer Battery Status LED

Status and ErrorIndicators of the CPU

Memory Reset

Mode Selection

FW Update ...

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PCS 7 BOX

PCS 7 BOX – Bill of Materials for Operator Station / Controller

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

Included Standard “Out of the Box”Included Standard “Out of the Box”

Runtime Only

Runtime OnlyOperator

StationOperator Station

AS / OSAS / OS

6ES7650-2HB06-0YX0

++



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PCS 7 BOX

PCS 7 BOX – Bill of Materials for Operator Station / Controller with Integrated Engineering

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

Included Standard “Out of the Box”Included Standard “Out of the Box”

Runtime Runtime Configuration

Configuration

AS / OS / ESAS / OS / ES

Operator Station

Operator Station

Engineering Station

Engineering Station

++


6ES7650-2HA06-0YX0


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PCS 7 BOX

Scalability & Upgradability of PCS 7 BOX

Operator Station

Operator Station

250 Process Objects

250 Process Objects++


Small ScaleSmall Scale Large ScaleLarge Scale

2000 Process Objects


250 Process Objects

250 Process Objects



Operator Station

Operator Station

Engineering Station

Engineering Station

++


Standard Package (Default)Standard Package (Default)

Process Object:Process Object: Any control element that has a

corresponding faceplate in the HMI

Any control element that has a

corresponding faceplate in the HMI

MotorMotor

PID Controlle

r

PID Controlle

rAnalog

IndicatorAnalog

Indicator

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PCS 7 BOX

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 Choose from catalog ST 80 or 3rd party

24 VDC Industrial Power Supply Recommendation is SITOP from CA01 Catalog

I/O Modules Order from Catalog ST PCS 7 based on project requirements

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PCS 7 BOX

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

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PCS 7 BOX

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

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PCS 7 BOX

Questions ?Questions ?

Thanks for Listening !Thanks for Listening !

1 Automation and Drives "DCS in a Box" SIMATIC PCS 7 BOX 6/2004 SIMATIC PCS 7 BOX The "DCS in a Box"

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