SMART DCS When failure is not an option

Distributed Control System (DCS) refers to a control system used in process control or continuous manufacturing which the controller elements are not centralized in a location but

are distributed throughout the system. Each components subsystems are controlled by one or

more controllers. The entire system of controllers is connected through a network for

communicating, controlling, and supervising.

In the fast changing industry of process automation, it is not just about technology and control,

but more importantly, it is about getting the job done correctly. There is a rising demand for

more critical advanced control system with greater management features to improve the entire

enterprises competitiveness and competence, to reduce energy consumption and pollution,

and to achieve sustainable development.

As a leading supplier in automation control industry in Egypt, PEP ARAB developed new

generation control system platform SMART DCS, based on international advanced

automation control technology. The SMART DCS brings you the next evolutionary step

providing better information visibility, critical control, performance, and operational agility.

It is an open system platform that is extremely reliable, flexible to configure by providing a

complete solutions to your plant automation needs.

SMART DCS is our new generation DCS, a hardware and software platform for the modern

automation industries demonstrating high state of art technology. Delivering the perfect

process control and overall enterprise level management, the SMART DCS platform is

developed to be used in the process industries. Examples of industries application are thermal

power, nuclear power, oil and gas, petrochemical, chemicals, pharmaceuticals, paper and

pulps, metals and minerals, cement, beverage, glass, metallurgical, water treatment, and

environmental protection.

System Philosophy SMART DCS is a system at which intelligent existing every where, intelligent distributed in all

levels, from field, up to Man Machine Interface at control room.

It means that each part of system can perform its function directly without any need to send

data to masters for processing purpose. Ability to monitor, operate & diagnose from all levels.

Smart DCS philosophy based on important facts:

Fact 1: each end intelligent could work independently. Fact 2: Possibility to process, monitor & operate from all levels.

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SMART DCS has a simple and common architecture covers a variety of plant sizes and industries.

SMART DCS Architecture divided into:

Operator Level

Process Level

Communication Level

These three basic levels support facilities from the tiny to very large and complex with up to

100,000 tags

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SMART DCS Operator Level Operator level contains the functions for operation and observation, archives, and logs,

trends, and alarms. Open-loop and closed-loop control functions are processed in the

controllers.

The SMART DCS operator stations use PC hardware, either standard or industrialized in line

with the application, running under the Microsoft Windows operating system. Operator station

supports dual-monitor operation, meaning that two monitors can be used on a single PC,

operated using one mouse and one keyboard.

One engineering station and several operator stations can be installed at the operator level.

The SMART DCS engineering station is used to configure and commission the system.

Usually, portable equipment such as laptops, which allow configuration both in the office and

on site, is used. The operator level PCs can also be used as engineering station. A

permanent connection to the engineering system is not necessary

SMART DCS Process Level At the process level, SMART DCS system can consist of several process stations that are

connected with I/O units. You have the option of running these process stations either

redundantly (CPU redundancy, fieldbus module redundancy) or without redundancy.

Modular plug-in input/output modules are used in accordance with the type and quantity of

process signals. SMART DCS Communication Level At Operator Level The data communication of operational level is known as system network (SNET). SNET is

used for data and resource connection, sharing, and printing between engineer station,

operator stations and system Historian.

SNET is redundant-capable to support real-time industrial Ethernet with star, loop, or bus

topology structure. It follows the IEEE802.3 and IEEE802.3u standards with adaptable baud

rate of 10/100Mbps and uses category 5 twisted pair and optical fiber with RJ-45 connection

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as transmission medium. Based on a reliable industrial Ethernet communication protocol, the

transmission of data can be more open, real-time, and reliable.

At Process Level The data communication of control level is known as control network (CNET). CNET adopts

PROFIBUS- DP industrial fieldbus to communicate with SMART I/O modules and devices or

instruments in automation system, in order to deliver real-time, speedy, and efficient process

or field communication tasks. It follows the IEC61158 international standard (national

standard JB/T10308.3-2001/European standard EN50170).

PROFIBUS-DP adopts poll communication between the master and slave stations with a

maximum baud rate that achieves 12Mbps, ideally. PROFIBUS-DP link can be connected to

a maximum of 126 nodes (0~125). Multiple communication mediums are applicable,

including twisted pair, optical fiber, or a mixture of both. Maximum communication distance of

twisted pair can reach 1.2km, while single-mode optical fiber can reach 10km, with complete

diagnosis function to facilitate system maintenance.

Hardware SMART DCS system hardware includes the following:

Engineer Station Engineer Station consists of a high-performance computer with DCS configuration software.

It is used to perform DCS configuration and upload operational parameters to the field control

station and operator station.

Operator Station Operator station consists of high-performance computer with optional touch screen HMI

display. It issued to monitor the production process, conduct controls, and check the running

status of the system network, controllers, and I/O modules in field control station.

Field Control Station Field control station consists of the field controllers, I/O modules, power supply modules,

terminal modules resides in the control cabinets. It does signal collection, conversion, various

controls and interlock algorithm, field signal output, etc. It also performs self-diagnosis of its

operational status. SMART DCS offers SMART I/O series modules for flexible configuration.

System Server (optional) High-performance server is used to fulfill the management, accessing, data processing, and

communication of real-time database and historical database. System server supports

redundancy and can be configured according to project scale.

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System Features

Adopting industrial Ethernet technology, to ensure real-time communication, to improve stability, network security, and safety.

Adopting the widely used PROFIBUS-DP fieldbus technology, to achieve the following advantages:

o Fulfilling decentralized risks and control, as well as centralized supervision in real time.

o I/O modules can be centralized or decentralized as per field situations to save cable costs.

o PROFIBUS-DP was accepted in 2001 as the fieldbus standard for the industrial automation industry.

o Systems and equipment following this standard have been widely applied in various industries. Hence, Smart DCS can

easily communicate and exchange data with field devices or

instruments from different suppliers or different branding.

Flexible system architecture equips with wide I/O ranges from tens to hundreds of thousands to adapt to different application.

Open system: The system supports and provides OPC industrial standard interface based on

COM/DCOM technology to standardize software interfaces between equipment

and application programs from different suppliers.

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Profibus-DP

In 1999, PEP ARAB utilized the profibus-DP core

technology with physical and link layer of the master

and slave stations

System Functions SMART DCS contains as minimum the following Functions:

Sequence Control

Steady State and Dynamic Control

Advanced Control

Process Data Collection

On/Off Switching

Alarm & Event Generation/handling

Graphic Displays

Group Displays

Loop Displays

Alarm Summary Displays

Trending (Real Time and Historical)

System Diagnostics

Computational Functions

Logging and Reporting Functions

Interfacing with other systems

Run application Programs

Features & Functions

Operator Level - Hardware Benefits

Operator Level Stations use commercial-off-the-shelf Industrial PC hardware with

Possibility for redundant of hard disk, the industrial PC in line with the application running

under the Microsoft windows operating system.

Plenty of horsepower: all operator level stations use state-of-the-art processors well suited to provide the performance required for SMART DCS software.

Lots of memory: all SMART DCS workstation come with sufficient memory to handle SMART DCS applications.

Secure data: up to RAID 10 controllers available with the workstation maximize data protection.

Crystal Clear Video: SMART DCS software works at 1024x768, 1280x1024, or 1680x1050 pixel resolution. An integrated video controller boosts video

performance to meet the resolution you demand. And increase the viewing space

with dual monitors.

Sounds alive: to provide the audible alarms for your automation project, 16-bit sound is included on the motherboard of all workstations.

Communications Security: SMART DCS system is solid, secure, and safe. SMART DCS control network is fully redundant and the workstations are

equipped to take advantage of this redundancy.

Monitors: SMART DCS include different types of monitors, a single monitor LCD 21 for Engineering and Historian stations, dual monitor LCD 21 for

operator Work Stations and Large LCD 50 monitors for maximum viewing area.

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Operator Station

The Operator Stations are mainly used for operation and monitoring. It displays process

variables, control parameters, and alarms necessary for users to quickly grasp the operating

status of the plant. It also incorporates open interfaces so that the supervisory computers can

access trend data, message, and process data. Operator Station Dual monitors support:

Operator station supports dual monitor operation, meaning that two monitors can be

used on single PC, operated using one mouse and one keyboard. Dual Monitor Benefits:

Expand the number of applications visible to a single operator.

Expand the usable screen space for a single operator.

Optimize operator interface for efficient use of the larger screen area.

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Hardware Structure of Field Control Station Field control station consists of control racks, controllers, power supply modules, smart I/O

modules, terminal modules, communication network, and control cabinets. Controllers and

smart I/O modules have built-in real-time operating system and I/O module operating

software, as well as complete LED indicators showing their operational status.

Control racks, controllers, power modules, smart I/O modules, terminal modules, and

communication network are all located inside field control cabinet. The cabinets can be

installed in the control room or distributed on site.

Hardware & Application Features SMART DCS modules are designed to be reliable, advanced, and easy-to-use. The following

are their technical features:

The physical structure of controller is independent from I/O modules, all

Controller supporting hot swap features for easy maintenance.

Main controller adopts high shock-proof and low power consumption CPU

working without fans for a longer and safer operational period. (CPU fans in

industry field usually last no more than 2 years) The long period power

consumption for the entire controller is less than 10 watts. All CPU and memories

inside the controllers adopt SMT or DIP insertion mode to improve its shock-

proof performance.

Power modules are small, light, and highly efficient, with powerful anti-

disturbance, wide input voltage ranges.

SMART IO modules, built-in micro-controllers, supporting Profibus-DP slave

station interface.

Isolation between field and electrical system, partial AIO inter-channel isolation,

DI optical coupling isolation, DO optical-coupling or relay isolation.

Automatic power-on for controllers and I/O modules with normal working

conditions status.

Main Controller and SMART I/O series modules have different features in terms of

structure and installation to meet the requirements of various industrial applications.

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Hardware Reliability SMART DCS features the following reliability technologies:

Redundancy Controller Redundancy

Controller's redundancy is used with one primary and the other standby. It is designed

with hardware redundancy, shift and fault self-detect circuit. Two controllers receive

network data and make calculation at the same time but only one output the calculated

results and updates the real-time data. Once the primary controller fails, the standby

unit will be shifted to work as the primary without any disturbances.

Power Supply Redundancy Modules Power modules are specially designed in redundant configuration, in case one power

module fails, the other will take over the entire power load.

I/O Redundancy AI/AO equipments are configured in redundancy.

Network Redundancy Industrial Ethernet interfaces with redundancy are configured for the controller with

embedded Profibus-DP master station interface.

Distribution and Isolation SMART I/O series, mounted in rails, can be centralized, distributed or remotely

distributed. Barrier circuit (channel isolation for AI/AO, optical-coupling isolation for DI,

optical-coupling isolation or relay isolation for DO) prevents disturbance from the

system. Channel isolation is able to eliminate the damage caused by field potential

difference.

Easy Maintenance Self-diagnosis

With embedded controller, each module is able to have periodic self-diagnosis,

including the following:

o DO channel: read-back, comparison, and self-diagnosis. o AI channel: adopts special input channel fault-diagnosis technology, diagnoses

and checks open circuit, short-circuit and jump.

o AO channel: adopts special output channel fault-diagnosis and diagnoses output channel and executor.

Status Indicators There are LED indicators in all modules and controllers, including running indicator,

error indication and network communication indicator. The running status of all modules

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is clear. At the operator station, operators can call the system status graphic to monitor

the running status of each station or each module.

Support hot swap. Controller support hot swap, which enables easy maintenance in case that any module

fails, all input/output signals are connected to terminal module. I/O signal enters I/O

module through terminal module. No wiring changes are required when the I/O module

needs replacement.

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Specification A large-scale SMART DCS can include multiple groups of servers. System can be divided

into multiple domains. Each domain consists of certain number of engineer stations, operator

stations, system servers, and field control stations, to enable relatively independent data

collection and equipment control functions. Engineer station and operator station can operate

on different domains by login.

Maximum Capacity Engineering domain 8 Server 1 pair per domain (redundant)

Engineer station 16 sets per domain, 1 set per domain in normal conditions, multiple engineer stations allowed.

Operator station 32 sets per domain Field Control Station 64 sets per domain Controller 1 pair per control station (redundant)

I/O Modules 126 nodes (0~125) per control station ( 72 per control station is recommended for decentralization)

System Margin Controller CPU peak load rate < 40% Memory margin Around 25% Data network load rate < 20% Power supply load margin > 40% Reliability MTBF 50,000h System availability 99.9% Response Time Minimum real-time data scan cycle 50ms Minimum loop control cycle 50ms Minimum logic control cycle 50ms Real-time image response time 1s System Network Communication protocol IEEE802.3/u, TCP/IP or industrial Ethernet protocol Network structure Real-time industrial Ethernet Communication medium Twisted pair category 5 or fiber optics Baud rate 100/1000Mbps Control Network Communication protocol Profibus-DP Network structure Bus Communication medium Shielded twisted pair or fiber optics Baud rate 1.5Mbps, 500kbps, and/or 45.45kbps (Profibus-PA link)

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System Precision

AI error 0.2% AO error 0.2% SOE time resolution 1ms Signal Interface AI signal type, I/O range 0~10V, 0 (4) ~20mA Thermocouple signal type J, K, N, E, S, B, R, T RTD signal type Pt100 AO signal type 4 ~ 20mA (max load 750 ) DI signal type Dry contact / 220AC level / 24DC

DO, maximum load capacity Transistor output: 50mA/30VDC; Relay output: 4A/220VAC, 1A/110VAC

Pulse Input, maximum frequency 10KHz (positive pulse) Power Supply

AC input voltage 220VAC(-15% ~ +10%), 50/60Hz2Hz 110VAC(-15% ~ +10%), 50/60Hz2Hz

Power supply for redundancy 1:1 flow equalization redundancy Input output isolation pressure resistance 3000Vrms EMC Electrostatic discharge immunity test IEC61000-4-2 1995 level 3 Electrical fast transient/burst immunity test IEC61000-4-4 1995 level 3 Surge immunity test IEC61000-4-5 1995 level 3 Radiated, radio-frequency, electromagnetic field immunity test IEC61000-4-3 1995 level 3

Immunity test for conducted disturbances induced by radio-frequency fields IEC61000-4-6 1996 level 3

Voltage dips, interruption and voltage variations immunity test IEC61000-4-6 1996 level 3

System Working Environment Working temperature Controller 0C ~60C Smart I/O modules 0C ~70C Storage temperature Controller -15C ~ 65C Smart I/O modules -40C ~ 85C Working humidity 5~95% relative humidity, non-condensing Storage humidity 5~95% relative humidity, non-condensing Ingress Protection Controller IP40 Smart I/O modules IP20 Cabinet IP32 or IP65 (optional) Vibration and shock Vibration range Maximum 7.5mm (5~9Hz) Acceleration Maximum 2.0g

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Overview PEP ARAB Control Systems incorporates powerful controllers for secure, mission-critical

operations such as those of power and water plants.

The SMDCS Controllers execute simple or complex modulating and sequential control

strategies, performs data acquisition functions, and interfaces to the Smart DCS Network

and various I/O sub-systems. It has the capability to originate up to 6,000 points.

The open architecture of the SMDCS Controllers uses a powerful real-time operating

system running on PCI bus PC architecture. This design allows rapidly advancing

technology to be easily integrated into the system - protecting your investment in software.

The SMDCS controllers are a family of rail-mounted modules, consisting of CPUs,

communication modules, power supply modules and various accessories. Several CPU

modules are available that vary in terms of processing power, memory size, and

redundancy support.

Each CPU module is equipped with Ethernet ports for communication with other controllers

and for interaction with operators, engineers, managers, and higher level applications.

The connectivity and expansion options make the SMDCS exceptionally open and

scalable, that is, easy to connect to the surrounding world of supervisory systems and

intelligent devices of all kinds - and adaptable to changing requirements as the process it

controls changes or expands.

Features & Benefits

By offering two controller models to choose from depending all on your

application and size of installation.

Fast processor for increased productivity

Secure, reliable and mission-critical control capability providing automatic

failover between redundant controllers

One-step data acquisition functionality through the definition of the I/O

database

Small footprint with low power requirements and fan less operation

Interfaces to SMART I/O Series, both local and remote

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Non-volatile storage of application software, point database, configuration

information, and operating tuning constants

Managed by a commercial, real-time operating system which supports multi-

tasking and preemptive task scheduling

Integrated sequence of events capability with 1 millisecond resolution

Meets IEC 61131-3 Standards

SMDCS-CP series modules have different features in terms of structure and installation to meet the requirements of various industrial applications.

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The SMDCS-CP Controllers

SMDCS-CP Controllers are Compact-PCI standard CPU with feature Intel Mobile Pentium-

M processors and offer fast execution, larger

memory capacity and upgradeability to track

future technology growth. The SMDCS-CP CPU

is available with various processor speed,

memory sizes, and performance capabilities

and advanced Functionalities, such as software

configuration of data and program memory.

The SMDCS-CP Controllers deliver high PC

computing performance in a highly integrated

cost-effective design.

The SMDCS-CP Controllers Combining the low power/high performance features of Intels Mobile Pentium processor with the 855GME chipset, the CPCI system controller

incorporates components commonly used in industrial and mobile applications.

Compact designed the single slot processor card integrates Intels latest I/O Controller

Hub technology. This all together results in lower levels of heat dissipation, which in turn

leads to lower system requirements and integration costs

Highly versatile the CPU can be used in a system or peripheral slot. With full hot swap

and IPMI functionality the CPU is an ideal solution for cost-effective, performance-

oriented data and telecommunications applications, media gateways, networking and

switching applications, airborne and industrial automation systems and more.

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The SMDCS-CP CPU Features:

Processor Mobile low power Intel_ Pentium-M processor in Micro-FCBGA 479-pin package

Low power dissipation.

High performance up to 1.8GHz

All board versions are passive cooled with a heat sink within 4HP height.

Forced air cooling at a specific flow rate is required depending on the processor version.

Memory Up to 2 GB DDR SDRAM

Socket for Compact Flash Type II module

1 MB Firmware Hub (FWH) for BIOS

8 kB for storing CMOS data when operating without battery

Front Panel Functions Ethernet: 2 x RJ45 with integrated LEDs (ACT, SPEED)

COM: 1x 9-pin D-Sub connector

LEDs: Thermal, Watchdog or both general purposes

Control: Reset button

Supervisory Functions Watchdog, software configurable, 125 msec to 256 sec

Generates IRQ, NMI or hardware reset, two stage configuration for NMI and

Reset

Hardware monitoring SCH3112 for thermal control, fan-sense/control and all

important onboard voltages

Compliancy Designed to meet or exceed:

- Safety: UL 1950, UL 94, CSA 22.2 No 950, EN 60950, IEC 950

- EMI/EMC: EN 55022 / EN 55024, EN 50081-1 / EN 6100-6-2

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Controller Rack

Complete 19 rack for 3U CPUs which have the following

features:

Backplane: From 2 up to 8 slot segments

Industrial Power supply: High end version with input from 85 to 260 VAC or from 18 to 36 VDC

Highest Quality: EMI protected, CE conform

SMDCS-CP Controller Redundancy

Now you dont have to worry about a controller failure interrupting your process and

causing costly downtime. Using a SMDCS-CP redundant controller, your process is

automatically protected in case of a failure.

When an active controller fails, the standby controller takes over, providing uninterrupted

control operation without initialization or user intervention.

The switchover generates no disturbances to the field output signals; the process

continues as though nothing had happened.

The automatic switchover protects you if either controller should fail. If the active

controller fails, the standby controller automatically becomes the active controller. A

message is sent to the operator indicating that switchover has occurred. If the standby

controller should fail, the software generates a message to the operator and switchovers

are disabled until the failed unit is replaced.

Some of the events that can cause a switchover are:

Hardware failure within the active controller

Communications failure between the active controller and I/O

Communications failure on both control network ports

Removal of the active controller from the rack

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You should always attempt to use pairs of the same controllers for backup, to

ensure proper processing.

Benefits

Uninterrupted control operation: Using the capabilities of the SMDCS-CP Controller, you can establish a safety net to protect your process from unexpected controller failures.

Automatic commissioning: The system automatically commissions a standby controller as its installed. You dont need to bring the system down to add redundancy. Addressing

and configuration are automatic.

Bumpless transition: You can add redundancy to an existing system as your needs grow. Redundancy adds minimal processing overhead to the system, allowing you to add

increased reliability without having to increase the processing capability.

SMDCS-CP Profibus DP Interface

The SMDCS-CP Profibus DP interface is a field-proven interface for Smart I/O series,

discrete actuators and sensors. It is easy to install, reliable, and simple to use.

High data throughput, simple installation, good diagnostic capabilities and error-free

proven transmission technology make the SMDCS-CP Profibus-DP a good interface

solution for complex devices.

The Profibus DP bus structure permits step-by-step commissioning of the additional

stations without influencing existing stations. Future expansions have no effect on

stations already in operation.

You can rely on SMDCS-CP Profibus DP cards to provide real-time, consistently accurate

inputs and outputs. As the network of field devices grows, maintenance remains constant.

Redundant Profibus DP Master: SMDCS-CP provides both a single or redundant Profibus DB Master solution with Smart I/O stations and smart instruments.

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Ordering Information Product Code Product Description

SMDCS-CP-DPM-S Complete single controller with 1.8GHZ Processor, 4-slot 19" 3U CompactPCI Rack, Power supply module, Profibus-DP master interface and system configuration software license

SMDCS-CP-DPM-R Complete redundant controller with 1.8GHZ Processor, 4-slot 19" 3U CompactPCI Rack, Power supply modules, Profibus-DP master interfaces and system configuration software license

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SMART I/O series is an intelligent concept for distributed control system

[DCS] resulting from the close contact

we have attained with our customers.

Hence, it offers a feature set that has

been designed and tested to satisfy the

daily needs of automation and together

with its unique fieldbus flexibility, it covers the growing demands for versatile connectivity

across all branches of industry.

SMART I/O Series has been developed with the requirements of their users in mind and as

such has an unprecedented level of modularity integrated in to their design concept. this allows

all functional units like CPUs , Fieldbus interfaces or power supply modules to fit exactly to the

application requirement without additional costs being passed on to the customer an

expanding palette of plug-in analog , digital and communication modules provide standard

sensor interfacing to these SMART I/O Family.

With the SMARTI/O Family PEP ARAB introduces an intelligent distributed control system [DCS] concept of excellent connectivity and modularity.

With these SMART Family equipped with a choice of fieldbus connection, the benefits of DCS are made available to a wide range of automation branches like industrial automation,

transportation or process control.

The features provided by the SMARTI/O Family help to bring a clear automation structure to

any given application with the added consequence of reduced planning, assembly and

installation costs. This is fact is the true concept behind the SMART2 I/O Family when

considering the pre-production of Plant modules each controlled by these SMART Family

controller. All Plant module functionality can be programmed and tested prior to final assembly

there by allowing separate tasks to be engineered simultaneously that helps to reduce project

schedule times

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The modularity inherent within the ingenious design concept of SMARTI/O systems allows an enormous flexibility in system configuration through the specific targeting of Fieldbus,

CPU or I/O modules to suit the application.

The open architecture of SMARTI/O Family guarantees availability for tomorrows demands be it another fieldbus interface, I/O module or CPU [SMART2]

SMART I/O Modularity: a wide range of I/O modules for SMARTI/O Family is available to interface the variety of process signals connected with industrial automation or process

control.

The comprehensive range of available modules covers digital I/Os, relay connections, analog

I/Os, serial communication and temperature processing interfaces.

With enough potential for up to 14 SMART modules, completely configured Family of SMART

I/O systems have enough driving force to equip even the most demanding industrial

application with up to 108 digital I/O points.

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SMART2- Base SMART2 system comprise up to five SMART2-Base units depending on the application

requirements. Designed as an expandable concept, up to 4 base units, each containing three

SMART module I/O slots can be accommodated on the DIN-Rail beside the first or master

base unit. Each SMART2-Base, equipped with 3 slots, automatically routes the internal I\O

bus and power supply lines to the next base unit. Thus, the complete system can be easily

tailored and configured to accept all needed I/O modules. The SMART2-Base recognizes if

CPU module is plugged into the first slot of the first unit and if so, performs the role of system

master.

The process interface of each slot is composed of two pluggable screw terminal blocks for

simple wiring and service handling.

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SMART2- CPU Designing the CPU in the same manner as the pluggable

SMART-modules opens a new area of flexibility in the micro

controller market.

An obvious Spin OFF is the easy creation of made to measure

systems for improved cost efficiency of a given application and

the ability to easily exchange or upgrade the modules.

The CPU-Modules, SM2CPU is equipped with Motorolas power

full MC 68LC302 microprocessor. Operating at a comfortable 20

MHz, theses CPUs are complete with 1.5 Mbyte DRAM

respectively, application software and firmware are stored in

1Mbyte of service Free flash memory that may be programmed via an RS 232 serial

interface built into the front panel an additional 256 Kbytes of SRAM is provided for system

and application use. Beside the dedicated modem compatible RS232 interface for

programming, a second serial line can be utilized for the connection of an operator panel.

Finally a supervisor utility resets the system if the power supply falls be low 4.65W.

The CPU, complete with all firmware installed, is ready for programming and downloading of

application code. Using either the IEC1131-3 dedicated PLC programming languages or ANSI

C, application code can be easily constructed. Updating, customizing and maintaining the

firmware and software is a simple procedure that takes advantage of the integrated bootstrap-

loader.

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SMART PROFIBUS DP (SM2-DP) The PROFIBUS module SM2-DP,

piggybacked to a SMART2 CPU, provides

the DP Slave interface. It is based on the

PROFIBUS SPC3 controller and

communicates with its master on all

standard baud rates up to 12 MBaud. The

micro-controller aboard the module covers

all protocol stacks handling autonomously

thereby offloading the system CPU from any

fieldbus overhead.

PROFIBUS communication is physically realized by an integrated opt isolated RS485 interface

with its standard 9-pin D-Sub connector.

Complying with the EN 50170 standard, PEPs PROFIBUS slave interface aboard the

SMART2 is designed to communicate with master systems such as PEPs VME and

CompactPCI or third party DP-devices. Data exchange along a network containing SMART2

slaves is possible as either I/O point or internal data point. Because the SMART2 is an

intelligent DP-slave device, it always provides pre-processed data i.e. a freely configurable

virtual data image.

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SMART Digital Input Module (SM-DIN1) The SM-DIN1 is a general purpose digital input module. Designed with 6 independent input

groups, the module offers a high level of flexibility when connecting process signals with

different potential groups.

8 opt isolated 24V DC digital inputs 6 independent groups Common GND Over voltage protection LED channel status indication

SMART Digital Output Module (SM-DOUT1) The SM-DOUT1 is a versatile digital output module that simplifies actuator connection. With a

duty cycle of 1:1, it can fully load all channels simultaneously and can switch at a maximum

frequency of 1 kHz. In addition, inductive loads may be driven without

damage to the module.

8 opt isolated 24V DC digital outputs 2 independent groups Common Vcc (high-side switch) 500mA continuous output current Over voltage protection Inductive load protection LED channel status indication

SMART Power Supply Module (SM2-DC24V1) The SM2-DC24V1 is an 18V to 36V / 10W DC/DC converter

purposefully designed to suit a fully loaded SMART2 system and

features additional digital outputs, continuous short circuit protection

and extended operating temperature capabilities.

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SMART Analog Input Module (SM-ADC1) SM-ADC1 is a high-resolution and opt isolated A/D converter module that supports current or

voltage inputs. The six differential inputs offer high distortion immunity that is important for

industrial environments. An on-board EEPROM stores unique calibration and gain/offset data

required by the signal converter.

6 differential & opt isolated inputs 10V DC or 0/4..20mA input range 12-bit ADC with 1-bit non-linearity 50s conversion time Over voltage protection 2 user configurable LEDs

SMART Analog Output Module (SM-DAC1) SM-DAC1, available in several different configurations, handles 12-bit DAC tasks with an

exceptional repeating accuracy. The short conversion time of 75sec (per channel) transforms

the SM-DAC1 into a powerful digital/ analog system. Unique calibration and gain/offset data

are stored in an on-board serial EEPROM.

2/6 differential & optoisolated analog outputs 10V DC or 0..20mA output range 12-bit DAC with 1-bit non-linearity 11-bit repeating accuracy 2 user configurable LEDs

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SMART Thermocouple Module (SM-THERM) SM-THERM supports up to four groups of R, S, B, J, T, E or K thermo element sensors

together with a cold-junction for extremely accurate temperature measurements. Designed

around a fast 16-bit delta-sigma A/D converter, the SM-THERM ensures an absolute

measurement accuracy of 0.2C over the complete operating temperature range of -210C to

+1820C.

4 thermocouple input groups One, 2-wire PT100 input for cold-junction Open sensor detection Self calibration (on-board EEPROM) Over voltage protection 2 user configurable LEDs

SMART PT100 Module (SM-PT100) The SM-PT100 is used for 2, 3 or 4-wire temperature measurement using PT100 sensors

driven by an on-board constant current source. Capable of connecting sensors measuring

temperatures between -200C and +850C, the SMTHERM uses a fast 16-bit delta-sigma A/D

converter that ensures an absolute measurement accuracy of 0.2C.

2, 3 or 4-wire PT100 sensor inputs Open sensor detection Self calibration (on-board EEPROM) Over voltage protection 2 user configurable LEDs

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SMART DCS Sequence of Event (SOE) Module Overview

When a process upset occurs, events can take place very rapidly throughout your process

area. In order to correctly determine the cause of the upset, accurate recording and

sequencing of the events is essential. Sequence of Events provides a means of recording the

events associated with a process upset, and using highly accurate time stamps to determine

the precise order in which they occurred

System Description

The SMART DCS system is designed to capture and time stamp the events as close to the

source as possible, providing you with a much more accurate picture of the sequence of

events as they occurred.

The SMART DCS system receives process-upset signals using the Sequence of Events input

module. This module with 30 discrete input channels and each channel is configured as SOE

input.

Benefits Captures process-upset events close to the source for faster recording: Sequence of Events (SOE) input modules are used to capture process- upset events coming

directly from devices in the field.

Provides increased resolution of timestamps for more accurate event sequencing: Events captured by an SOE input module are time stamped using a 1 millisecond resolution.

Additionally, the time stamps are resolved by the SMART DCS controller to ensure accuracy

across the SMART DCS network. Using a Network Time Protocol (NTP) server

The NTP server uses the Global Positioning System satellites for an accurate time reference.

As the controller reads events, they are time stamped using the NTP server as a reference.

This method of synchronization, along with the increased resolution, provides a much more

accurate and complete picture of the order in which the events occurred.

Easily integrates data with desktop applications for detailed analysis and reporting. The Event Chronicle stores these events electronically, so that you always have easy, reliable

access to the data. A single Event Chronicle can capture system events spanning multiple

SOE - Sequence of Event

controllers and workstations, so that you can look in one place to find all the relevant data.

Additionally, multiple Event Chronicles can reside on the same Smart DCS network for

redundant event capturing. The events stored in the Event Chronicle can be easily viewed

using the Process History Viewer application, which displays the events in chronological order.

The Event Chronicle can automatically export data as well, so that it can be read using other

software packages such as the standard Microsoft Office applications.

Sequence of Event Digital Input module

Characteristics

Function : 30 SOE independent opto isolated digital input channels

Input Voltage Range : 12V DC to +80V DC

Input Current : 4.2mA (per switched input)

Max. Input Rating : 10V DC < Vin < 230V DC

Input Frequency : 20 kHz (max.)

Switching Level : 10V = high

Scan Rate : 0.25 ms for all 12 channels

Switching Char. : ton = 25s, toff = 11s

Input Protection : Reverse voltage protected

Common

Isolation : 2500V DC between I/O and system; 100V DC between

inputs

Power Req. : +5V DC ( 5%), 50mA typ.

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Smart DCS System Software Overview Smart DCS provides user-friendly HMI, powerful programming and simulation software that

takes care of the configuration of all functions and data storing and processing capability that is

able to record important historical data and provide reports.

The power of all these functions lies in the software structure and technology. Client/Server

structure is adopted by Smart DCS operating level to guarantee data coherence,

completeness and safety, featuring good flexibility and expandability.

With COM/DCOM, middleware technology and OPC technology, Smart DCS software system

supports and provides OPC interface based on COM/DCOM technology. With standard OPC

interface, data communication between instruments of different suppliers becomes easier to

maintain and no special interface programming is necessary.

Human Machine Interface (HMI) With Smart DCS HMI, the operators are able to get the whole process information, browse the

flow chart, quickly identify various events, and input the required control parameters to ensure

safe operation of the various equipments. In addition, with corresponding authorization,

operators, maintenance engineers, and managers are able to track the process, modify

process parameters, and obtain reports.

Engineering Flow Chart All the measuring points monitored by the control system can be displayed using

graphics icons or symbols including digit, current value, dimension, value ranges

with upper and lower limits.

Support multi-level display structure, display levels can be designed according to engineering procedure and

running sequence.

The graphics can be called in various modes such as menu mode, movable window display, automatic pop-up

display, hot point call and keyboard call.

Software Tools

Alarms Smart DCS alarm function helps and reminds the operator to

solve sudden in case of abnormal status or equipment failure

status during the production process. Alarms are categorized

into process alarm, equipment alarm and SOE signal alarm.

Reports Smart DCS software provides integrated report system, which can print all the measuring

points in the database. The measuring points in the report can be printed in formats defined by

users. Automatic printing or manual printing is optional.

Logs SMART DCS software provides logging functions which can automatically records, stores, and

checks all the sudden events in sequence and provides detailed evidence for managers to

analyze the events.

Logs can be classified into daily log, equipment log, operation log, SOE log and simplified log.

Logs can be displayed in track mode and historical mode. In track mode, the system will

automatically display the most recent information. In historical mode, historical event can be

displayed. All event information, operation parameter setting events, alarm monitor and timing

information are grouped into different logs.

Historical Trend SMART DCS software records all information of the measuring points in a database and

displayed either in the form of data or charts, featuring with

flexible modified time axis ranges or parameter axis ranges.

Trend curve provides monitoring platform for plant managers

or administrator to know if the production process is safe and

effective.

Various trends can be displayed such as general trend.

General trend deals with both analog and digital trend

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information. Digital trend takes care of digital trend information and functions as modification

query.

General trend can be displayed in track mode and historical mode. General trend can be

displayed in curve. Maximum of 16 measuring points trend can be displayed for analog and

digital trend. And the curve display range scope is real-time modified according to the curve

fluctuation displayed on the screen to easily identify the change of curve. The operator is

allowed to select or shield this function.

Powerful Configuration Software Smart DCS provides user-friendly, powerful programming, and simulation software to configure

all system functions and collectively control and manage the whole project execution. The

software consists of system equipment, database, control calculation, graphic, report, off-line

simulation, and on-line management. It provides an integrated platform to design your

graphical Interface and control strategy.

Integrated Database Integrated database stores all configuration data and settings. Database configuration is to

define and edit the measuring point information, including actual physical measuring points

and Mid-variables.

Large Graphical Libraries SMART DCS HMI graphical layout and design software enables users to design a direct and

clear operational user interface. With the help of the large and

practical graphical libraries (ISA Symbols), users are able to

easily draw complex and beautiful graphic such as animation,

data, curves bar charts and real-time display of all the devices

and instruments or display complicated tables for any data type.

Smart DCS software also provides dynamic icons to indicate the

running status of equipment and parameter value as real-time

dynamic points. Users are also allowed to have personal graphic library and store frequently

used graphic in the library as icons for repeated usage.

Powerful Control Strategy Generation Tool

Software Tools

Consist of control calculation editor and simulation debugger, the control strategy generation

tool allows you to write control algorithms through programming, downloading, and simulating.

Control Strategy Programming Smart DCS control strategy generation tool provides rich function block calculation library, like

IEC operator, type transfer function, timer, trigger, counter function, emergency events

function, PID control, fuzzy control and sequence control. Users are also allowed to add self-

defined functions. Typical industrial control algorithms, like batch control, PID loop, complex

loop, logic loop, hybrid loop, advanced control calculation and special recipe control can be

fulfilled by using library function.

User Programmable Functions Smart DCS control strategy generation system allows users to have further development on it,

providing self-defined functions and function blocks. Users are able to program complex

control modules with six programming languages and embed them to the system.

The control strategy configuration interface adopts an explorer-like window with tree-structures

to display the control solutions and set basic attributes, like solution name, used language,

calculation cycle, calculation switch and sequence.

On-line Download without Disturbance All databases in SMART DCS system can be downloaded to the

controller. The system provides specific reminding and warning

information during the download. Modified incremental files can

also be downloaded to the controller without disturbing system

running.

Convenient Off-Line Simulation Environment Smart DCS provides off-line simulation environment. Users are allowed to debug the control

algorithms configuration in non-field environments like at home or offices. Under the simulation

mode, program can run independently from the controller. Breakpoint, monitor variable, single-

step execution, single-loop execution, jump execution, call execution, call stack check, flow

control, value modification and forced output can be set during simulation.

On-line Modification

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The system supports on-line modification. Users can login the controller to modify auxiliary

information like range without affecting the running system and process. Meanwhile, users are

also allowed to force output and input variables and cancel the forcing.

Breakpoint setting, monitoring variable, single-step execution, single-loop execution, jump

execution, call execution, call stack check and flow control can be applied.

Access Security To prevent unauthorized access to database and configuration data, the smart DCS provide

several access levels under password or key-lock control

Smart DCS Access Level includes:

Operator Level: Operator level permit normal operator access for:

- Loop manipulation

- Start/Stop, Open/Close function

- Alarm acknowledgement & reset

- Call up of all operator displays

- Trend Selection

- Alarm printout facilities, Historical printout

- Reports

Engineer Level: Engineer Level permit access to operator function as above

and additional give access to:

- Database facilities for editing, generation and backup of both global and area

database

- Loop configuration and tuning facilities

- Display building Facilities

- Programmable Functions

- System network and node diagnostics facilities

- Generation of log and Reports

Supervisory Level: Supervisory have access for all functions listed for operator

level additionally have access to loop tuning parameters, process range,

operator alarms settings

View Only: The process may be viewed, while data entry or process changes

are not possible

Software Tools

Printing - The SMART DCS provide facilities for printout of:

- The system database configuration and programs

- HMI displays

- Custom historic trends of process and calculated variables

- Real time trends of selected variables

- Event logging, including operator keyboard actions

- Process parameter deviations from their set point

- Trip alarms and SER alarms

- Reports

- System diagnostics

Supports Six Industrial Standard Programming Languages SMART DCS adopts IEC61131-3 configuration tools and provides six standard industrial

programming languages LD, FBD, ST, SFC, IL and CFC for different industrial control

applications.

LD-Ladder Diagram LD is continuous executing language used for basic logic control,

consisting of contacts (normal open/ close, positive slope

triggering, negative slope triggering, reversion), coil (output,

mono stability, lock, unlock, jump), connection, timer and

counter. LD is good at quick discrete logic control, including

motor control, interlock, random check and simple sequence control.

FBD-Function Block Diagram FBD: a Graphical function blocks language, enabling

calculation and control. FBD consists of basic function blocks,

links and input/output terminals and prescribes the call

sequence of all function blocks and parameters required by

corresponding module calculation.

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ST-Structural Text ST is used for complex control applications composed of some key

characters and instructions, like symbols (key characters,

operators, modifiers, and operands), statements (expressions,

control statements), functions and function blocks. Control solutions

can be programmed taking character line as the unit.

SFC-Sequence Function Chart SFC is used as the connection between continuous control or logic control and input/output

monitor to describe and control the sequence operations of the

process events, applying to events with plenty of status controls.

SFC consists of a series of steps and transitions, each step

including a group of actions affecting the process. SFC supports

concurrent sequence and diversified qualified characters.

Each action can be fulfilled by any of the above four languages.

IL-Instruction List IL is the most fundamental computer programming language. It can

be simply operated with abundant content.

CFC-Continuous Function Chart CFC is similar with FBD but there is no node in CFC.

Software Tools

The contents of this publication are presented for informational purposes only, and while every effort is made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our software licensing agreement, and terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our product at any time without notice. 2009 PEP ARAB Control Systems CO. The PEP ARAB logo is a trademark and service mark of PEP ARAB Control Systems Co.

Address : Block 12 I Industrial Zone , Gamasa , Dakahlia Egypt

Phones: +2 050 2770211, 12, 13, 14

Fax: +2 050 2770211

Website : www.peparab.com

E_mail: peparab@peparab.com

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