MAC PI Industry

1
The "DCS in a Box"
SIMATIC PCS 7 BOX
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Agenda

• Introduction Overview
• System Architectures
• More Details on the Industrial PC
• More Details on the Controller
• Packaging and Bundling
• Summary
• Questions Answers

3
Trends in Process Automation
Controller
Controller
Controller
PC
Intelligent Field Devices
PC
1990
2000
2010
PC-based Process Automation Solutions are
becoming more prevalent
Distributed Architectures are required to meet
tomorrows business needs
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Trends in Process Automation...
Market Studies of DCS System Architecture by ARC
Number of Small Plants (x 1000)
According to ARC, business drivers are pushing
customers to install Small systems
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Trends in Process Automation...
Hardware Cost per Small Plant (x 1000)
The market demands a continuous reduction in the
cost of process automation system hardware
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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 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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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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Key Design Considerations for PC-based control in
Process Industries
Considerations

• 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

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Physical Dimensions of PCS 7 BOX
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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PCS 7 BOX is offered in two flavors
Software is Preinstalled on the PC
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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
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
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Three Possible System Architectures
Architecture
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.
2.
3.
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Standalone Operator Station / Controller
Download Control, HMI Configuration
Configuration from a Remote (floating)
Engineering Station
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Standalone Operator Station / Controller with
Integrated Engineering
Configuration is done using the Integrated
Engineering capability
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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
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More Details on the PC
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SIMATIC Box PC 620 high performance in a small
form factor
Designed for use in Industrial Environments
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SIMATIC Box PC 620 expandable to meet your
needs
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SIMATIC Box PC 620Technical specifications
Subject to technical changes/improvements without
prior notice.
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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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SIMATIC WinAC Slot CPU
Memory Card (RAM/Flash)
MPI/DP Interface (external)
LED Stop/Run
Connector forbackup 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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CPU Panel
Buffer Battery Status LED
Mode Selection
Memory Reset
Status and Error Indicators of the CPU
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PCS 7 BOX Bill of Materials for Operator
Station / Controller
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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PCS 7 BOX Bill of Materials for Operator
Station / Controller with Integrated Engineering
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

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Scalability Upgradability of PCS 7 BOX
Large Scale
Small Scale
Operator Station
250 Process Objects
2000 Process Objects

Controller
Operator Station

Controller
250 Process Objects
2000 Process Objects

Engineering Station
Standard Package (Default)
PID Controller
Motor
Analog Indicator
Any control element that has a corresponding
faceplate in the HMI
Process Object
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SIMATIC PCS 7 Box Optional Accessories
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PCS 7 BoxGoing 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 BoxGoing 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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Questions ?
Thanks for Listening !