Distributed Control Systems

Hollias Macs-K System

HOLLiAS MACS-K is a large DCS developed by HollySys for process automation applications. It uses reliability-oriented design technologies such as full redundancy and multiple isolations. The system also incorporates the design concept used for safety systems, hence guaranteeing the long-term stable operations of the system.

Profile of HOLLiAS MACS-K system

The HOLLiAS MACS-K is based on industrial Ethernet and PROFIBUS-DP fieldbus structure, with integration being based on the HART standard protocol’s HAMS to centralise the on-site management of intelligent instruments. It is able to easily integrate systems such as SIS, PLC, MES, and ERP, enabling seamless data communication between on-site intelligent instrument equipment, control system, and the ERP, creating a centrally controlled smart factory.

At the same time, the system integrates the advanced control algorithms of different industries such as the thermal power industry and the chemical industry, providing in-depth and comprehensive solutions for factory automation control and enterprise management, resulting in the best coordination of production, equipment, and safety, helping users control their costs and maximise their equipment investment returns within the shortest life-cycle possible.

Characteristics of the HOLLiAS MbrACS-K System Safety and Reliable

Full Redundancy

System network, control network, controller, power modules, and I/O modules can be configured for redundancy, and do not have single-point faults. Multiple isolations: Fiber-optic isolation is used between the system bus and modules; electric isolation is used between modules, and power isolation between site power supply and the system power supply.

Reliable Design

The system is designed to be hardy in harsh industrial environments, equipped with anti-electromagnetic interference device that is compliant with IEC61000, and corrosion resistance that satisfies the G3 requirements under the ISA S71.04 standards.

Safety Network

A reliable real-time Ethernet is used for the system’s network that is equipped with firewall-equipped switches. A PowerPC structured industrial chip that is inbuilt with anti-network storm components is used for the controller CPU.

Extensive Diagnostics

The controller and I/O module is equipped with smart diagnostic units, and each module is capable of complete self-diagnosis and failure reporting for failure and statuses such as communication status, signal disconnection, short circuit, and over range.

Highly Reliable Design Concept

Many safety system designs and concepts were adopted to make the system more reliable, such as determining signal quality bits, failure-oriented safety, and checksum of all data transmitted.

Flexible and Open

Supports 3 types of system network structures such as P-to-P (peer network), C/S (client / server), P-to-P and C/S (mixed).

Supports industrial Ethernet with star, ring, and bus topology.

Compatible with different types of fieldbuses, and supports protocols such as HART, PROFIBUS-DP, PROFIBUS-PA, and MODBUS. The HMI (human machine interface) is full of features, and the software is coded with control algorithms compliant with IEC61131-3 standards.

Supports user-defined function modules and scripting languages.

Able to flexibly modify control algorithms and hardware components, and download with ease on-site after modify without stopping.

The system design takes into account the user’s ease of usage, maintenance, and replacement, while providing complete information on system status and diagnosis.

HOLLiAS MACS-K System Structure

Complete MACS-K system comprising components such as engineer stations, operator stations, history stations (optional), site control stations, and industry control networks.

MACS-K Engineer Stations

System network, control network, controller, power modules, and I/O modules can be configured for redundancy, and do not have single-point faults. Multiple isolations: Fiber-optic isolation is used between the system bus and modules; electric isolation is used between modules, and power isolation between site power supply and the system power supply.

MACS-K Operator Station

Complete management of monitoring and control of production site. The interfaces are standardised, and the processes are monitored in real-time.

MACS-K Control Station

Complete on-site signal acquisition, engineering unit conversion, control, and lock control algorithms, control output, using system network to send data and diagnostic results to the operator station, and other functions. It is possible to configure the controller for redundancy, and the minimum control execution cycle is 10ms. At the same time, the station has strong diagnostic capability.

MACS-K history station: Complete system historical data service and exchange of data with the factory management network.

The system’s network structure from the top down comprises 3 layers, which are the management network (MNET), system network (SNET), and the control network (CNET).

Management network: This is an optional layer used to communicate with factory-level production management systems such as MES and 3rd party management software, and it can disseminate data securely through the internet, sharing and managing data at a higher level.

System Network: Connects nodes such as the engineer station, operator station, history station, and control station, supporting network structures such as P-to-P (peer network), C/S (client/server), or a combination (mixed) of P-to-P and C/S. It is possible to rapidly establish a safety network with a high-speed redundancy using a star, ring, or bus topology that complies with the IEEE80 2.3 and IEEE802.3u standards, with a self-adaptive communication speed of 10/100Mbps.

Control Network: Used to connect the main controller of the control station and different I/O modules and intelligent instruments, supporting star and bus topography, which complies with the IEC61158 (International standard JB/T10308.3-2001, European standard EN50170) standards, ensuring that on-site communications are real-time, stable, and fast.

HOLLiAS MACS-K System’s Key Functional Indicators

Work Environment

Working temperature: -20-60℃

Working humidity: Relative humidity of 5%-95%, no condensation

Storage temperature: -40 – 80℃

Storage humidity: Relative humidity of 5%-95%, no condensation

Vibration amplitude: Max.1mm (5-13.2Hz)

Impact: Max.7.5m/s² (13.2-100Hz)

Protection level: IP20

Environmental adaptability: Compliant with Level G3 of ISA S71.04

Electromagnetic Compatibility

Electrostatic discharge immunity: Compliant with IEC61000-4-2

RFEMS (Radio-Frequency Electromagnetic Field Immunity): Compliant with IEC61000-4-3

Electrical fast transient burst immunity: Compliant with IEC61000-4-4

Surge (impact) immunity: Compliant with IEC61000-4-5

Immunity to conducted disturbances induced by RF fields: Compliant with IEC61000-4-6

Immunity to voltage dips and short interruptions: Compliant with IEC61000-4-11

System Scope
  • Supports a maximum of 15 domains
  • Operator station: 64 machines / per domain
  • Site control station: 64 machines / per domain
Real Time Response Capability
  • SOE event resolution: <1ms
  • Time from control key inputs to the corresponding output of changes < 1s
  • Controller task scheduling cycle: 50ms, 100ms, 200ms, 500ms, 1s
  • Time taken to update screen data: < 1s