19'' Subrack Solutions for Distributed Control Systems (DCS)

The Mechanical Backbone for Flexible & Reliable Industrial Control

As smart manufacturing and flexible production lines accelerate, the traditional pyramid-style automation architecture is rapidly giving way to decentralized, modular Distributed Control Systems (DCS).

In this transformation, the Subrack has become the preferred mechanical platform for DCS field nodes—thanks to its high-density layout, hot-swappable modules, and full redundancy design.

Subracks are no longer“just enclosures.”They are the physical foundation enabling the next generation of modular, scalable, and downtime-free industrial control.

Technical Challenges---What Industrial Users Struggle With in Modern DCS Projects

1. Expansion or process changes require shutdowns

Conventional cabinets are rigid, wiring is fixed, and any modification often means prolonged downtime.

2. Single-point failures can bring the entire line to a halt

Most field nodes lack redundancy in power, cooling, and communication.

3. Complex wiring and long commissioning cycles

Point-to-point wiring increases labor cost and makes FAT time-consuming.

4. Higher bandwidth demands from Ethernet, PROFINET, EtherCAT

Optical fiber is becoming essential, but many systems lack high-density fiber management.

5. Low mechanical reuse across machine models

Different machine types require different enclosures, driving up R&D and inventory cost.

Subrack technology directly addresses these challenges—enabling modular expansion, continuous uptime, and fast deployment.

Key Compatibility Indicators for Your DCS Project:

• Form Factor: 19” subrack, 3U/4U height, 84HP width

• Module Capacity: Up to ~12 I/O, communication, or safety modules per frame

• Redundancy: Dual power input, dual fan groups, hot-swappable maintenance

• Connectivity: Front quick-connect, rear terminal block, IP67 options

• Fiber Management: Up to 96 × MTP® ports (1152 fibers) within 4U

• Protocol Compatibility: Industrial Ethernet, PROFINET, EtherCAT, fiber ring networks

• Reuse Ratio: 90% cross-model module reuse

Why Subrack Is Becoming the Standard for Modern DCS

How Subrack Enables Modular, High-Availability Control Systems

1. The Ideal Base for Modular Machines

Build complete micro-DCS nodes inside one frame

The essence of DCS is pushing control closer to the machine.

With a 19” frame and 84HP horizontal mounting rail, a single subrack can house up to 12 I/O, communication, or safety modules—forming a complete decentralized controller.

Benefits:

• Process changes = swap or add modules

• No rewiring required

• Zero-downtime expansion for flexible manufacturing

2. Full Redundancy: Make Shutdowns a Thing of the Past

Keep your production running 24/7

Subrack power and cooling modules are engineered for industrial-grade redundancy:

• Dual-feed power supply

• Dual fan group

• Hot-swappable modules

Even if a module fails, the system continues at 100% load, ensuring production continuity for process-critical industries such as petrochemicals, energy, food, and pharmaceuticals.

3. Less Wiring, Faster Commissioning

Reduce engineering hours and shorten FAT cycles

With front-mounted quick-connect interfaces (IP67 options available), Subrack eliminates the need for traditional control cabinets.

Results:

• Wiring workload reduced by 40%+

• FAT can be performed directly on the production floor

• Overall delivery cycle reduced by ~15%

4. High-Density Fiber Management: 288 to 1152 Fibers in One Frame

One subrack can carry the entire line’s data backbone

As Ethernet-based fieldbuses migrate to fiber, Subrack offers a high-density FO-DCS solution supporting:

• Up to 96 × MTP® (1152 fibers) in a 4U chassis

This makes gigabit/10-gigabit communication between distributed nodes simple and highly scalable.

5. 90%+ Reusability: Dramatically Lower Machine Cost

Build new machine models like assembling LEGO®

Thanks to standardized mechanics, I/O, communication, and safety modules can be reused across machine variants.

• Over 90% reuse rate

• Reduced R&D and inventory costs

• Minimal spare parts needed

• Up to 30% savings in on-site maintenance

Subrack: The Physical Foundation of Next-Generation DCS

Subrack technology is:

• The mechanical anchor for decentralized DCS architecture

• A catalyst for flexible, modular, and scalable machinery

• A key enabler of zero-downtime, high-availability automation

Choose Subrack for your next distributed system—simplify control, accelerate deployment, and keep your production running without interruption.