Automation and Drives
The "DCS in a Box"
"DCS in a Box"
SIMATIC
PCS 7 BOX
SIMATIC PCS 7 BOX
6/2004
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Automation and Drives
Trends in Process Automation...
"DCS in a Box"
SIMATIC
PCS 7 BOX
Market Studies of DCS System Architecture by ARC
HMI/ES Stations
Controllers
Analog I/O's
Digital I/O's
CAGR Number of Systems
CAGR Average Selling Price
Numbers in 2001
Small
1-2
1-2
0-299
0-599
3.3%
-9.5%
11600
Medium
3-8
3-8
300-799
600-1499
2.3%
-10.8%
8900
Large
>8
>8
800+
1500+
0.6%
0.3%
2000
Number of “Small” Plants (x 1000)
13.5
13
12.5
12
11.5
11
10.5
10
2000 2001 2002 2003 2004 2005
According to ARC, business drivers are pushing customers to install “Small”
systems
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Automation and Drives
Trends in Process Automation...
"DCS in a Box"
SIMATIC
PCS 7 BOX
Hardware Cost per Small Plant (x $1000)
30
25
20
15
10
5
0
2000 2001 2002 2003 2004 2005
The market demands a continuous reduction in the cost of process
automation system hardware
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Automation and Drives
To respond to these business drivers, Siemens has introduced PCS 7
BOX – The “DCS in a Box”
"DCS in a Box"
SIMATIC
PCS 7 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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Automation and Drives
Potential Advantages of a PC-based Solution
"DCS in a Box"
SIMATIC
PCS 7 BOX
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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Automation and Drives
Key Design Considerations for PC-based control in Process
Industries
"DCS in a Box"
SIMATIC
PCS 7 BOX
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
PCS 7 BOX Design

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
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Automation and Drives
Physical Dimensions of PCS 7 BOX
"DCS in a Box"
SIMATIC
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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Automation and Drives
PCS 7 BOX is offered in two flavors
"DCS in a Box"
SIMATIC
PCS 7 BOX
Functionality
Operator Station
Software
Runtime Only
AS / OS
+
Controller
6ES7650-2HB06-0YX0
Functionality
Operator Station
Software
Runtime
Configuration
+
Controller
+
Engineering Station
AS / OS / ES
6ES7650-2HA06-0YX0
Software is Preinstalled on the PC
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Automation and Drives
PCS 7 BOX shares common hardware and software with PCS 7, providing an
unprecedented level of scalability
"DCS in a Box"
SIMATIC
PCS 7 BOX
Pilot
Plant
Manufacturing
plant
Scalable
from PCS 7 BOX...
Multiple plants at a
manufacturing site
...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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Automation and Drives
Three Possible System Architectures
"DCS in a Box"
SIMATIC
PCS 7 BOX
Architecture
1. Standalone Operator Station /
Controller
2. Standalone Operator Station /
Controller with Integrated Engineering
Local Operator Station / Controller
3. with connection to PCS 7 system
Application
 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
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Automation and Drives
Standalone Operator Station / Controller
"DCS in a Box"
SIMATIC
PCS 7 BOX
Download Control, HMI
Configuration
Configuration from a Remote (floating) Engineering
Station
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Automation and Drives
Standalone Operator Station / Controller with Integrated
Engineering
"DCS in a Box"
SIMATIC
PCS 7 BOX
Configuration is done using the Integrated
Engineering capability
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Automation and Drives
Local Operator Station / Controller with connection to PCS 7
Network
"DCS in a Box"
SIMATIC
PCS 7 BOX
Single, Central Engr Station
can be used to configure PCS
7 Box and the PCS 7 Network
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Automation and Drives
More Details on the PC
"DCS in a Box"
SIMATIC
PCS 7 BOX
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SIMATIC Box PC 620 –
high performance in a small form factor
Automation and Drives
"DCS in a Box"
SIMATIC
PCS 7 BOX
Designed for use in Industrial Environments
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SIMATIC Box PC 620 –
expandable to meet your needs
Automation and Drives
"DCS in a Box"
SIMATIC
PCS 7 BOX
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Automation and Drives
SIMATIC Box PC 620
Technical specifications
"DCS in a Box"
SIMATIC
PCS 7 BOX
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 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
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Automation and Drives
SIMATIC WinAC Slot CPU
"DCS in a Box"
SIMATIC
PCS 7 BOX
 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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Automation and Drives
SIMATIC WinAC Slot CPU
"DCS in a Box"
SIMATIC
PCS 7 BOX
Memory Card
(RAM/Flash)
MPI/DP Interface
(external)
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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Automation and Drives
CPU Panel
"DCS in a Box"
SIMATIC
PCS 7 BOX
Buffer Battery
Status LED
Mode Selection
FW Update ...
Memory Reset
Status and Error
Indicators of the CPU
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Automation and Drives
PCS 7 BOX – Bill of Materials for Operator Station / Controller
"DCS in a Box"
SIMATIC
PCS 7 BOX
Functionality
Operator Station
Software
Runtime Only
AS / OS
+
Controller
6ES7650-2HB06-0YX0
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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Automation and Drives
PCS 7 BOX – Bill of Materials for Operator Station / Controller with
Integrated Engineering
"DCS in a Box"
SIMATIC
PCS 7 BOX
Functionality
Operator Station
Software
Runtime
Configuration
+
Controller
+
Engineering Station
AS / OS / ES
6ES7650-2HA06-0YX0
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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Automation and Drives
Scalability & Upgradability of PCS 7 BOX
"DCS in a Box"
SIMATIC
PCS 7 BOX
Operator Station
+
Controller
Operator Station
+
Controller
+
Engineering Station
Small Scale
Large Scale
250 Process Objects
2000 Process Objects
250 Process Objects
2000 Process Objects
Standard Package (Default)
Process Object:
Any control element that has a
corresponding faceplate in the HMI
PID Controller
Motor
Analog
Indicator
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Automation and Drives
SIMATIC PCS 7 Box Optional Accessories
"DCS in a Box"
SIMATIC
PCS 7 BOX
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
“Going Where No DCS Has Gone Before”
"DCS in a Box"
SIMATIC
PCS 7 BOX
Automation and Drives
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
“Going Where No DCS Has Gone Before”
Automation and Drives
"DCS in a Box"
SIMATIC
PCS 7 BOX
Applications

OEMs to the Process Industry

Skid Vendors (“Smart Skids)

Secondary Processing

Pilot Plant Applications

Stand-Alone or Networked Architectures
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Automation and Drives
"DCS in a Box"
SIMATIC
PCS 7 BOX
Questions ?
Thanks for Listening !
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