Distributed Control System

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What is DCS?

 Distributed Control System

is a computerised control system for a process or plant usually with a
large number of control loops, in which autonomous controllers are
distributed throughout the system, but there is central operator
supervisory control.

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Application

 Chemical plants  Sewage treatment plants

 Petrochemical (oil) and refineries  Food and food processing
 Pulp and Paper Mills  Agro chemical and fertilizer
 Boiler controls and power plant  Metal and mines
systems
 Automobile manufacturing
 Nuclear power plants
 Metallurgical process plants
 Environmental control systems
 Pharmaceutical manufacturing
 Water management systems
 Sugar refining plants
 Water treatment plants
 Agriculture Applications

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DCS Product Range

HS-DCS-1000
HS-2000
Hardware FM
SM
K
HOLLiAS MACS MACS V1
MACS V2
SmartPro
Software
MACS V4
MACS V5
MACS V6

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DCS Hardware Evolution

5 generation of HOLLiAS MACS Hardware:

HS-DCS-
HS-2000
1000 FM Series SM Series K Series
(1995)
(1993) (2000) (2004) (2013)
obsolete
obsolete

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FM-Series

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FM-Series

System Scale
 Up to 127 I/O DP Slave
 Up to 2000 I/O points per FCS
 Analog control loop up to 128
 Typical motor digital control loop up to 256

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SM-Series
redundancy configuration redundancy configuration redundancy configuration
100M 100M
Ethernet Ethernet
24V DC 24V DC 24V DC 24V DC 48V DC 48V DC A B
Power Power Power Power Inquire Inquire
supply supply supply supply power power
100M 100M
Switch Switch
B A

AC220V Redundancy output DC24/48V Redundancy input HollySys HollySys HollySy s HollySys

AC220V Input A
AC220V Input B
SM935 SM942 NULL NULL SM 220 SM 220

S NET1
B
SNET B
SM150
S NET2

S NET1
A
SNET A
DC24/48V Redundancy output
S NET2

Inquire Controller
power rack
output

CNET
CNET
HollySys HollySys HollySys HollySys HollySys Hol lySys Holly Sys HollySys Hol lySys HollySys HollySys HollySys HollySys HollySys

A
B

24V DC input
NM910 NM 910 NM610 NM6 10 NM 610 NM 610 NM610 NM 410 NM410 NM 410 NM410 NM 410 NM 410 NM410

24V

OUT
TR
B

A
IN
B
RN RN RN

IO rack 1

CNET HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollyS ys HollySys HollySys

A CNET
B

24V DC input
NM910 NM910 NM 610 NM610 NM 610 NM610 NM610 NM 410 NM410 NM 410 NM 410 NM 410 NM410 NM410

OU T
TR
B

IN
B
RN RN RN

IO rack 2

CNET HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys HollySys

A CNET
B

The front view The rear view 24V DC input NM910

A
NM910 NM 610 NM 610 NM610 NM610 NM610 NM410 NM410 NM410 NM410 NM410 NM410 NM 410

OU T
TR
B

A
IN
B RN
RN RN

IO rack 3

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SM-Series

System Scale
 Up to 125 I/O DP Slave
 Up to 2000 I/O points per FCS
 Maximum 20,000 Communication Points per FCS

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K-Series

Fans

Redundant
Power Module

Discovery Power
Distribution Panel

Redundant
Communication Module

Redundant
Controller

IO modules &
Terminals

AC Power Supply
Distribution Panel

DC Power Supply
Distribution Panel

Guide Rail

Front Rear

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K-Series

System Scale
 Up to 100 I/O modules per FCS
 Maximun 3200 I/O points per FCS
 More than 100,000 I/O points per domain
 Up to 300 control loop

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Hardware Design Comparison

FM Series SM Series K Series

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FM-Series Controllers
FM820 & FM821

FEATURES HIGHLIGHTS
 Embedded x86 compatible processor
 1MB SRAM, backup battery
 Flash solid disc
 Redundancy configuration
 Double-redundancy industrial
Ehternet interface
 Built-in Profibus-DP master interface
 Hot swap
 Rail mounting

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FM-Series Controllers Comparison

Model FM801 FM802 FM820 FM821

Hardware Configuration
Embedded x86 Embedded x86 Embedded x86
CPU compatible processor compatible processor compatible processor
100 MHz 200 MHz 333 MHz
DRAM 16MB
SRAM 1MB
SSD (Solid State Disc) 8MB 32MB -
Cycle Time - 100 ms 50 ms
Communication
SNET Redundant industrial Ethernet, baud rate 10Mbps
CNET Profibus-DP field bus, baud rate 500kbps
Power Supply
Power Voltage 24VDC+5%
Power Consumption (Max) 10W@24VDC 6W@24VDC
Working Environment
Working Temperature 0oC – 45oC
Working Humidity 5 - 90% relative humidity, non-condensing
Storage Temperature -15oC – 65oC
Storage Humidity 5 - 95% relative humidity, non-condensing
Physical Features
Dimension 71.12 mm x 177.8 mm x 305 mm (W x H x D)
Installation Installed on rail and fixed with bolts
System Requirement
Software MACS V5 MACS V6
Installation Up to Windows XP or Windows Server 2012 Up to Windows 10 or Windows Server 2016

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SM-Series Controllers
SM220 & SM221

FEATURES HIGHLIGHTS
 Embedded 333MHz 32-bit Processor
 128M SDRAM
 16M Flash Data Storage
 1M SRAM, power-loss protection
 Master and Slave controller
redundancy configuration
 S-Net Redundancy Configuration
 C-Net Redundancy Configuration
 Dual DP communication transceiver
 Support PROFIBUS-DP protocol.
 Power-loss protection
 Controller hot-swappable

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SM-Series Controllers Comparison

Model SM202 SM203 SM220 SM221

Hardware Configuration
CPU 32-bit Embedded 32-bit Embedded 32-bit Embedded Processor, 333 MHz
Processor, 100 MHz Processor, 200 MHz
SDRAM 32 MB 128 MB
SRAM 1MB
Disk On Chip 1 GB 32 MB -
NOR Flash - 16MB
Cycle Time - 100 ms 50 ms
Communication
SNET Redundant industrial Ethernet, baud rate 10Mbps Redundant industrial Ethernet, baud rate 100Mbps
CNET PROFIBUS-DP protocol, redundancy configuration
Power Supply
Power Voltage 5.1VDC +5% 24VDC +10%
Power Consumption (Max) 10W@5VDC 6W@24VDC
Working Environment
Working Temperature 0oC – 60oC
Storage Temperature -20oC – 70oC
Relative / Storage Humidity 5 - 95% relative humidity, non-condensing
Physical Features
Dimension 40.45 mm x 162 mm x 132.39 mm (W x H x D)
Installation Rack slide-rail installation
System Requirement
Software MACS V5 MACS V6
Installation Up to Windows XP or Windows Server 2012 Up to Windows 10 or Windows Server 2016

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K-Series Controllers
K-CU01 & K-CU02

Features
 Support redundancy
 Support SNET redundancy
 Support CNET redundancy
 ECC check
 Up to 100 I/O modules

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K-Series Controler
K-CU03

Features:
 Support redundancy
 Single module support redundant INNER-BUS
master station
 Single module support IO-BUS master station
 Support redundant SNET
 With DDR ECC check
 Up to 2000 physical tags (for one control
station)
 Support 10 ms task scheduling cycle (fastest)
 Support expanding third-party interface by
increasing gateways

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SM-Series Controllers Comparison

Model K-CU01 K-CU02 K-CU03

Hardware Configuration
CPU PowerPC architecture, 32 bit, clock speed 333 MHz PowerPC architecture,
32 bit, clock speed 800 MHz
Program FLASH 16 MB
Memory 128 MB
SRAM 1 MB
Cycle Time 100 ms 50 ms 10 ms
Communication
SNET Redundant industrial Ethernet, baud rate 100Mbps
CNET PROFIBUS-DP protocol, redundancy configuration
Power Supply
Power Voltage 5.1VDC +5% 24VDC +10%
Power Consumption (Max) 4W@24VDC 14.4W@24VDC
Working Environment
Operation Temperature -20oC – 60oC
Storage Temperature -40oC – 70oC
Relative / Storage Humidity 5 - 95% relative humidity, non-condensing
Physical Features
Dimension 57.2 mm x 164 mm x 168.82 mm (W x H x D)
Installation Fixed with bolts
System Requirement
Software MACS V6
Installation Up to Windows 10 or Windows Server 2016

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MACS V6 Controllers Comparison

Fastest Power
  Cycle CPU Memory Consumption

FM820 100 ms SDRAM DDR2 128MB

SRAM 1MB
NOR FLASH 16 MB
FM821 50 ms NAND FLASH 128MB
6Wmax@24V
SM220 100 ms SDRAM DDR2 128MB
SRAM 1MB
32-bit 333 MHz NOR FLASH 16 MB
SM221 50 ms DPRAM 8KB

K-CU01 100 ms SDRAM DDR2 128MB

SRAM 1MB 4Wmax@24V
K-CU02 50 ms NOR FLASH 16 MB

K-CU03 10 ms 32-bit 800 MHz DDR3 512MB 14.4Wmax@24V

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System Architecture for MACS V5

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System Architecture for MACS V6

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Software

MACS MACS SmartPr MACS V4 MACS V5 MACS V6

V1 V2 o (2003) (2006) (2006) (2011)
(199x) (199x) • FM • FM • FM • FM
• xxx • FM • SM • SM • SM
• K

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MACS V5 and MACS V6

MACS V5 MACS V6

 Based on CodeSys  Self development

 Support FM and SM Series  Support FM, SM, and K Series
 Operating System:  Operating System:
 Windows XP SP 3  Windows XP SP3
 Windows Server 2003 R2  Windows 7
 Windows Server 2008 R2  Windows 10
 Windows Server 2003 R2
 Support up to 8 domains  Windows Server 2008 R2
 Max. 30 OPS per domain  Windows Server 2016
 Max. 40 FCS per domain  Supports up to 15 domains
 Max. 64 OPS per domain
 Max. 64 FCSper domain

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Software Comparison:
Components - MACS V5

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Software Comparison:
Components - MACS V6

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Software Comparison:
Main Program - MACS V5

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Software Comparison:
Main Program - MACS V6

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Software Comparison:
Hardware Configuration - MACS V5

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Software Comparison:
Hardware Configuration - MACS V6

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Software Comparison:
Database Editing - MACS V5

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Software Comparison:
Database Editing - MACS V5

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Software Comparison:
Database Editing - MACS V6

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Software Comparison:
FCS Programming - MACS V5

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Software Comparison:
FCS Programming - MACS V6

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Software Comparison:
Graphic Editing - MACS V5

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Software Comparison:
Graphic Editing - MACS V6

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Software Comparison:
Download - MACS V5

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Software Comparison:
Download - MACS V6

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Software Comparison:
OPS - MACS V5

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Software Comparison:
OPS - MACS V6

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Software Comparison:
System Diagnostic - MACS V5

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Software Comparison:
System Diagnostic - MACS V6

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MACS V6 New Features

• Support new K series hardware release

• Support K series controller with FM modules
• Support inter domain reference with M5 system
• Support Microsoft Windows 10 and Server 2016
• Web Access for CCTV Integration

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MACS K Series New Features

New Controller K-CU03

• CPU main frequency 800 MHz
• IEC Cycle, minimum 10 ms
• Support IRIG-B timing, higher accuracy
• Adopt INNER-BUS (PowerLink)
100M Ethernet
• Can be PowerLink master and DP master

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MACS K Series New Features

AI Modules
New I/O Modules
Model Channel scan cycle
K-AI01/K-AIH01 90ms/8 Channels
1. K-AI04 / K-DI04 / K-DI12 / K-DO02 ； K-AI02/K-AIH02 10ms/8 Channels
K-AI03/K-AIH03 120ms/16 Channels
2. K-AI04 don’t support redundancy ； K-AI04 0.5ms/8 Channels
DI Modules
3. K-DI04 support SOE, Time precision 0.25ms ； Model Channel scan cycle
K-DI01 1ms/16 Channels
K-DI11 1ms/16 Channels
K-DI03 1ms/32 Channels
K-DI13 1ms/32 Channels
K-DI04 0.1ms/16 Channels
K-DI12 0.1ms/16 Channels
DO Mudules
Model Load Capacity
K-DO01 Max. 50mA@Single Channel
K-DO02 Max. 2A@Single Channel

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Upgrade / Replacement Information

The latest version for M5 is MACS V5.2.5 only support Win XP

• SmartPro to MACS V5.2.5
• Change the MCU and dongle
• FM8xx change to FM802 (FM801 & FM803 are supported)
• M5.x.x to MACS V5.2.5
• Change the dongle
• FM and SM series
• SmartPro / M5.x.x to MACS V6
• Change the MCU, controller rack, and dongle
• FM8xx to FM820 / FM821 or SM2xx to SM220 or SM221
• Upgrade logic and HMI to MACS V6
• Upgrade OS to Windows 7 or Windows 10
• FM801 is not produce anymore. Any replacement of FM801,
will use FM802.

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