ECS/CONTROLCENTER™

PROCESS CONTROL
COMPLETE AND RELIABLE PLANT AUTOMATION
 LIFT PLANT PERFORMANCE
WITH ECS/CONTROLCENTER™
PROCESS CONTROL SYSTEM
Our process control solution is packed with features to efficiently
manage and troubleshoot your plant and equipment.

KEY BENEFITS

CyberSecure systems Hardware agnostic

Personalized interfaces
Easy to engineer and scale
supports user focus

Lifecycle reliability via Plantline

service agreements

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 PROCESS CONTROL FROM
THE PROCESS EXPERTS
With continuous need to control costs, improve operational efficiency, and
reduce environmental impacts, today’s process industries need a reliable
control system now more than ever. In FLSmidth Cement, you have the ideal
solutions provider.

We have been developing specialist automation software for process and

quality control since the 1970s. There are currently more than 2000 of our
ECS/ControlCenter control systems installed globally, about a quarter of which
control complete production lines. Tailored specifically to process industries,
the system integrates the in-depth process knowledge and machine-building
experience we have gained since delivering our first cement plant in 1887.

ECS/ControlCenter Evolution
Versions and support operating systems at release*

2023 2011 2001 1997

• ECS 9.0 • ECS V8 • ECS V7 • ECS V6
• Windows • Windows Server • Windows • Windows NT
Server 2022 + 2008 R2 + Server 2000
Windows 11 Windows 7

1975 1985 1992 1995

• SDR V1 • SDR V2 • ECS V3 • ECS V4
• HP A 32k • HP 1000 A 600 • DEC VAX • DEC Alpha
Open VMS Open VMS

*During an ECS version lifecycle it will typically support 2 OS versions for backwards and forwards compatibility.

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 RELIABILITY AND SECURITY
Reliability and security
The ECS/ControlCenter solution is designed to In addition, we can provide lifecycle
be depended upon. Server, network, and PLC cybersecurity services, including
redundancy ensures continuous operation, cybersecurity risk assessments and risk
including a unique dual-synchronised redundant mitigation, monitoring and response,
server configuration that creates a high- endpoint security, software updates,
availability cluster and ensures zero downtime backups, and disaster recovery planning.
with no loss of data in case of a server failure.

Our software adheres to IEC, ISA, and NIST

cybersecurity guidelines. A defence-in-depth
approach enhances security with access
control, tested patch updates, firewalls,
network segmentation, and endpoint security.
Extensive user access control settings allows
granular control of user permissions to prevent
unauthorised access and actions, while domain
integration enables plant-wide or enterprise-level
user authentication and authorisation.

SCALABLE, OPEN ARCHITECTURE

THAT’S READY FOR INDUSTRY 4.0
Software-centric Interoperability Scalable architecture
architecture and AI integration The ECS/ControlCenter
Here at FLSmidth We have also designed the ECS/ solution is easily scalable, able
Cement, we develop ControlCenter software for easy to accommodate individual
software solutions, not interoperability. It integrates with other touchscreen HMIs up to
proprietary hardware. It systems, both onsite or Cloud-based, complete plants within the
means our software is via open communications standards, same software. This includes
designed to be hardware including OPC-UA, MQTT, ethernet/IP, integration of multiple
agnostic, supporting Modbus TCP, and Profinet. Scheduled production lines into one central
best-in-class computer, data export in XML, CSV, Excel, PDF, control room. It can also be
network, controller, or SQL queries enable ERP and data securely extended to remote
and IO hardware from historian integration. And there’s operations centres for remote
the complete range of seamless and reliable integration with monitoring and operations, while
suppliers, such as Dell, open-source AI and data analytics a secure ECS Web app enables
Cisco, Siemens, Rockwell, tools using Jupyter Notebook and access to data from any device
Scheider Electric, Fortinet, Python, enhancing process control (mobile, tablet, PC) using
Beckhoff, and Phoenix with predictive insights and advanced secure progressive web app
Contact. diagnostics. technology.

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 ENGINEERING, INSTALLATION,
AND MAINTENANCE
DCS functionality Standard function
with PLC flexibility blocks
Based on our ECS/ACESYS™ advanced standard The use of standard function blocks
function block library, the ECS/ControlCenter delivers standardised, reliable plant
system offers a hybrid solution, combining the control, allowing for easy parameter
benefits of traditional DCS systems with the changes directly from the interface
flexibility of modern PLC/SCADA systems. without the need for specialised
The ECS programming library is PLC-brand programmers. The same user
independent, enabling a choice of Tier 1 process interface is used on touch HMIs,
automation controllers, such as Siemens S7 400 control room clients, servers, and
and 1500, Rockwell ControlLogix and Compact engineering workstations, which
Logix, and Scheider Electric M580. We don’t lock reduces maintenance complexity.
you into a proprietary architecture based on your
choice of PLC brand. Meanwhile, the ECS/ACESYS
function blocks are equipped with
Within the software, all objects are associated inbuilt device simulation, allowing
with a faceplate, which allows: full off-line testing of all start/stop
• Direct access to detailed information and sequences, interlocks, and alarm
diagnostics in real-time behaviours before installation; it
• Remote execution of device-specific commands is also used to provide realistic
• Easy modification of block parameters, such as scenarios for operator and engineer
PID settings, timers, etc. training.

Consistent and structured PLC programs

ECS/ControlCenter systems are typically engineered in our Metis
high-level engineering system. This automatically generates all
PLC programs from set templates to ensure standardisation and
consistency, resulting in a much higher level of quality and reliability
than can be expected from systems programmed manually.

1 Insert an ECS/ACESYS function block in the PLC program 2

and establish interlocks to surrounding devices. 1
Create a new tag with the matching object type
2 in ECS/ControlCenter and link it to the PLC address.

Drag the tag to a mimic diagram and connect the symbol

3 to other process objects with visual lines.

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 INTELLIGENT
AND USER-CENTRIC DESIGN
ECS/ControlCenter is built with the end-user in
mind. Operators and engineers benefit from an
intuitive interface that simplifies complex operations.
The system’s high-performance HMI allows easy
navigation through process mimics using touch or
mouse gestures, ensuring that critical information is
always within reach. The new dedicated Group Start
Panel Bar is an example of this. Providing a superior
status overview of the machinery before start-up, the
operator gets an at-a-glance view of the health of every
device in the group and all the interlocking states.

Personalized role focus

Modern plants are run by small teams where
operators handle multiple roles, which can make focus
challenging. Our control software addresses this by
configuring role responsibilities in the system to keep
operators focused. Upon login, operators select a role,
and the system adapts accordingly:

• The graphical interface to show relevant

departments
• Trend packages for these departments appear at Intelligent alarm management
the top.
• Alarm lists filter to show only pertinent alarms. The ISA 18.2-compliant alarm management system
This role-based focus simplifies the system, preventing helps operators detect and respond to abnormal
information overload in critical situations. User access situations as quickly as possible, with automatic
control configurations define operators’ rights, alarm suppression by hierarchy reducing the number
ensuring security by limiting access to privileged users. of nuisance alarms.

The event historian stores all alarms and events

for up to one year and provides advanced analysis
tools to help understand event history. Alarms
and interlocks can also be traced back to the root
cause, by cascading directly from faceplate to
faceplate. Each device individually registers what
problem caused it to stop and provides a link to the
associated device.

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 DATA MANAGEMENT,
VISUALISATION, AND REPORTING
The inbuilt data historian logs all process, alarm,
and event data for one year at full resolution, using
a ‘swinging door’ algorithm, which logs data only
when it changes to preserve disk space. Longer
time horizons are possible with an optional ECS/
PlantDataManagement server.

Trend anything any time

Simple report configuration
The trend system can be used to analyse any
combination of up to 16 analogue or digital tags SQL reporting tools are used to provide a simple
without an engineer or admin user. Pick from pre- interface to basic reporting functionalities, including
built trend packages, build your own, or simply drag daily, monthly and shift report. The built-in reports can
and drop tags onto the trend screen from the HMI. be configured with any analogue value or digital status,
The trend system is responsive, with most trends and can be scheduled for automatic printing or export
opening within 1-3 seconds; trend data can also be as required.
easily exported to a file for further data analysis.
Extensive data export capability
Data queries to export value and event data from the
ECS SQL database can be scheduled or triggered on an
event with the data exported to common file formats
(e.g., CSV, XML). Events can also be used trigger
actions, such as sending a SMS, email, or workplace
notification, or playing a sound. The database also
includes extensive calculate data that can be exported
(e.g. analogue value maximum, minimum, average, time
for given time period).

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 LIFECYCLE MAINTENANCE
AND SERVICE
We are just as dedicated to ensuring the system can be maintained to be reliable,
secure and up to date throughout its lifecycle. Our service and maintenance
applications help you monitor system performance with KPIs, manage
configuration, update software, and backup or restore the system.

Software updates and information is available on a product support website. We

regularly test all software in the active phase of support against Microsoft update
patches and provide a listing of tested and approved patches on the website.

We also provide full lifecycle service through PlantLine™ service agreements.

Preventative maintenance keeps your system running reliably, with 24/7 phone,
chat, or remote service available in emergency situations. Software subscriptions
are available to keep your system up to date and security patched, while our
cybersecurity services prevent attacks and system downtime.

PROACTIVE LIFECYCLE
Maintenance Access to the latest
services to reduce downtime
PLANTLINETM
software features

ESSENTIAL
REMOTE CORE MODULE CYBERSECURITY
TECHNOLOGIES Managed whitelisting
Plantline mobile app system hardening
Go2FLS

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 C 01-24 2000-9-ENG V3

www.flsmidth-cement.com
Copyright © 2024 FLSmidth Cement. All Rights Reserved. FLSmidth is a (registered) trademark of FLSmidth A/S,
and FLSmidth Cement is authorized to use the trademark under a license agreement. This brochure makes no offers,
representations or warranties (express or implied), and information and data contained in this brochure are for
general reference only and may change at any time.