SMART DCS

When failure is not an option

SYSTEM OVERVIEW

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.

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

SYSTEM ARCHITECTURE

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

ARCHITECTURE IN DETAIL

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

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.

ardware
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.

ARCHITECTURE IN DETAIL

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

Features & Functions

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.

Profibus-DP
In 1999, PEP ARAB utilized
the profibus-DP core
technology with physical
and link layer of the master
and slave stations

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

System Functions

SYSTEM HARDWARE

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.

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.

OPERATOR STATION

Operator Station

FCS - Field Control Station

ardware 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.

ardware & 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 shockproof performance.

Power modules are small, light, and highly efficient, with powerful antidisturbance, 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.

ardware 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

HARDWARE RELIABILITY

HARDWARE RELIABILITY

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.

pecification

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

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)

SPECIFICATION

SPECIFICATION

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

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

SMART DCS - CONTROLLER

Overview

SMART DCS - CONTROLLER

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

information, and operating tuning constants

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

SMDCS-CP

Controllers

are

Compact-PCI

standard CPU with feature Intel Mobile PentiumM 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, performanceoriented data and telecommunications applications, media gateways, networking and
switching applications, airborne and industrial automation systems and more.

SMART DCS - CONTROLLER

The SMDCS-CP Controllers

SMART DCS - CONTROLLER

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

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

SMART DCS - CONTROLLER

Controller Rack

SMART DCS - CONTROLLER

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.

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

SMART DCS - CONTROLLER

Ordering Information

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

SMART I/O SERIES

SMART I/O series is an intelligent

SMART I/O SERIES

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.

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.

SMART I/O SERIES

SMART2- Base

SMART I/O SERIES

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 bootstraploader.

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.

SMART I/O SERIES

SMART PROFIBUS DP (SM2-DP)

SMART I/O SERIES

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.

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

SMART I/O SERIES

SMART Analog Input Module (SM-ADC1)

SMART I/O SERIES

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

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

SMART DCS Sequence of Event (SOE) Module

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

: <5V = low, >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.

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

Smart DCS System Software

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

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

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

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 selfdefined 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, singlestep 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

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

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

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.

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

ST-Structural Text

SMART DCS

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