PlantPAx Process Automation System Selection Guide

PlantPAx Process Automation System Selection Guide
Selection Guide
PlantPAx Process Automation System
System Release 2.0 (2012 update)
PlantPAx Process Automation System
Selection Guide Scope
The PlantPAx™ Process Automation System has all the core capabilities expected in a world-class distributed control
system (DCS). The system is built on a standards-based architecture by using Integrated Architecture™ components that enable
multi-disciplined control and premier integration with the Rockwell Automation® intelligent motor control portfolio.
Our scalable platform provides you with the flexibility to implement a system appropriate for your application. With the
PlantPAx system, we prescribe a very specific system architecture with defined system elements, each with a specific
responsibility and detailed specifications. The PlantPAx system starts with controllers and visualization and expands with
FactoryTalk® Asset Management and FactoryTalk Historian software, batch, and advanced controls for a comprehensive process
automation system solution.
This PlantPAx Selection Guide is designed to step you through the selection of system elements for creating a bill of materials
for ordering your system. Using the prescribed architecture and recommendations explained in this manual, you can use the
PlantPAx System Estimator (PSE) in similar fashion to create an order if you have access to the Integrated Architecture Builder
(IAB) software. The PSE is part of the IAB tool. See page 8 for details.
Define
&
Procure
System
Setup &
C
Configuration
n
Application
Specific
Code
System
Test
CCommissionn
Support
System Elements
Servers and Workstations
Controller Hardware
I/O Components
Network Infrastructure
32238-MC
You do not need to read the sections in the order outlined on page 3. However, we do recommend that you start with the
Overview to acquaint yourself with the system elements and architecture that comprise the PlantPAx system.
What's New?
This revision of the Selection Guide updates system rules to support the latest software versions and 64-bit operating system as
well as provides additional guidance for system selection.
Topic
Description
Page
PlantPAx System Estimator (PSE)
Expanded the information provided for defining, building,
and sizing your system architecture by using the PlantPAx
System Estimator.
8
64-bit Microsoft Windows operating systems
Updated the PlantPAx system rules for 64-bit Microsoft
Windows operating systems.
9 (as example)
Catalog numbers
Added catalog numbers for Rockwell Automation
Integrated Architecture software to assist with purchasing
decisions after creating a bill of material (BOM).
10 (as example)
2
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Follow These Steps
1
System Elements and
Architecture
Review:
• PlantPAx system elements
• System architectures and sizing guidelines
Page 5
2
Servers and Workstations
Page 9
3
Controller Hardware
and Sizing
Page 21
4
I/O Components
Page 25
5
Network Infrastructure
Page 33
Select:
• PASS
• Engineering workstation
• Operator workstation
• Application servers
Select:
• Simplex controllers
• Redundant controllers
• Skid-based controllers
Select:
• I/O product family
• Communication interfaces
• Process networks
Select:
• Domain controller
• Network topology
• Ethernet switches
6
Advanced Process
Control
Page 37
Select:
• Regulatory control options
• Supervisory control options
7
Process Safety Systems
Page 41
Select:
• Logic-based safety system
• ICS Triplex safety system
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Select a PlantPAx System
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Table 1 - Additional Resources
Resource
Description
Knowledgebase Answer ID 62366 at http://www.rockwellautomation.com/knowledgebase/
PlantPAx Knowledgebase Table of Contents: Links to PlantPAx Library of Process Objects and
associated documents for tips and best practices.
ControlLogix System User Manual, publication 1756-UM001
Explains how to use traditional and extreme environment ControlLogix controllers.
ControlLogix Selection Guide, publication 1756-SG001
Explains how to select a ControlLogix® system based on your application requirements.
CompactLogix Selection Guide, publication 1769-SG001
Explains how to select a CompactLogix™ system based on your application needs.
FLEX I/O and FLEX Ex Selection Guide, publication 1794-SG002
Explains how to select a distributed I/O system for safe and hazardous environments.
POINT I/O Selection Guide, publication 1734-SG001
Explains how to select modular I/O modules for your system requirements.
Redundant I/O System User Manual, publication 1715-UM001
Explains how to install and set up the 1715 Redundant I/O system.
http://www.rockwellautomation.com/solutions/process/integrationdocs.html
Links to Process solution device integration documents.
http://www.endress.com/eh/home.nsf/#products/~products-instruments
List of instruments from Endress+Hauser
Ethernet Design Considerations Reference Manual,
publication ENET-RM002
Explains the infrastructure components that allow this open network to communicate seamlessly
throughout a plant, from shop floor to top floor.
Industrial Ethernet Media, Complete Solution for Ethernet Networks and Integrated Architecture,
publication 1585-BR001
Provides information on Rockwell Automation 1585 Ethernet cables.
Converged Plantwide Ethernet (CPwE) Design and Implementation Guide,
publication ENET-TD001
Provides information on Ethernet security and firewalls.
Region Locations for Panduit Corporation, Product category
Provides information on connected cabling systems and infrastructure management from
Encompass™ partner Panduit Corporation.
Using ControlLogix in SIL2 Applications Safety Reference Manual, publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
http://www.rockwellautomation.com/products/certification
Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
http://www.rockwellautomation.com/solutions/process
Provides general information about Rockwell Automation process capabilities. From the left-hand
menu on the home page, select DCS Migration Solutions for information on the DCS migration
program.
http://www.migratemyprocess.com/webinars
Features prerecorded webinars on the DCS migration program and capabilities for process
customers.
You can view or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical
documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
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Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
System Elements and Architecture
Welcome, and thank you for choosing the PlantPAx system for your
process control. This section provides an overview on the system
elements and architectures that comprise the PlantPAx system.
Process System Elements
Review these options:
• Process System Elements
• PlantPAx System Architectures
• PlantPAx System Estimator
• Software Release Information
To get started building your system, Table 2 summarizes the system elements that comprise a PlantPAx system. These elements
(combinations of hardware and software products) are explained throughout this guide with corresponding catalog numbers
to assist you with your equipment procurement.
Table 2 - System Element Descriptions
System Element
Description
Process automation system server (PASS)
The PASS is a required system element that serves as the main system host. The PASS provides central name resolution and lookup
services. The PASS also may host displays, alarms, and data connections to controllers.
Operator workstation (OWS)
The OWS provides an interactive graphical interface to monitor and control the process.
Engineering workstation (EWS)
The EWS provides a central location for configuring the system and monitoring/maintaining system operation.
AppServ-HMI
HMI application servers provide additional system capacity to the PASS or may be use to create logical segregation of application
content based on the process.
The number of HMI application servers depends on the operational areas of the plant, as well as the number of these components:
• Controllers
• Alarms, displays, data logs, and historian tags
• Operator workstations
AppServ-Information Management
The information management server provides data management functions, such as collection of historical data and providing
access to historical data to OWS and enterprise-level applications. The information management server also may host decision
support tools, such as real-time reports or dashboards publishing Key Performance Indicators (KPI) through a web browser.
AppServ-Asset Management
The asset management server acts as a centralized tool for managing automation-related asset information (both Rockwell
Automation and third-party assets). The asset management application server includes capabilities for source control, audits,
change notifications, reporting, and security.
AppServ-Batch
The batch application server provides comprehensive Batch Management, including unit supervision, recipe management, process
management and material management. The batch application server can be linked with visualization elements at the OWS and
configuration clients on the EWS.
Controller
The ControlLogix controller supports continuous process applications, including Advanced Process Control functions, with its
deterministic, time-based execution mode. The controller supports continuous, batch, discrete, and motion applications.
Physical location, application layout, and process layout may all affect the number of controllers needed in a PlantPAx system.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Select a PlantPAx System
PlantPAx System Architectures
Rockwell Automation characterizes the PlantPAx system based on its size or architecture class. A ‘characterized’ (system tested)
classification yields system performance data and recommended hardware and software configurations. The classes of
PlantPAx architecture offer system scalability while organizing IA products consistent with process industry expectations.
The architecture classes shown in the illustration are described as the following:
• Independent system architecture for single unit control
• Centralized system architecture for area control
• Distributed system architecture for plant-wide operations
Distributed
Centralized
Independent
Use these system elements in your process architecture.
Table 3 - Architecture System Elements
System Element
Independent Class
Centralized Class
Distributed Class
PASS
Single computer serves as PASS, EWS, and OWS in
an independent workstation
One PASS required and includes:
• FactoryTalk Directory server
• HMI server
• Data server
• Alarms and Events Server
One PASS required and includes:
• FactoryTalk Directory server
• HMI server
• Data server
• Alarms and Events Server (optional)(1)
Additional AppServ-HMI as needed
EWS
Included in independent workstation
• 1 EWS required
• Can have as many as 5 EWS
• 1 EWS required
• Can have as many as 5 EWS
OWS(2)
Included in independent workstation
8 remote clients
8 remote clients for PASS
8 additional remote clients (32 clients maximum)
for AppServ-HMI
Domain controller
N/A
Required if there are more than 10
workstations/servers on the network
Required
Process controller(2)
1...5 ControlLogix controllers
1...6 ControlLogix controllers
1...6 ControlLogix controllers for PASS (data server)
1...6 ControlLogix controllers for AppServ-HMI
(data server)
Application servers
None(3)
One AppServ-Batch
One AppServ-Information Management
AppServ-Asset Management
AppServ-Batch as needed
AppServ-Information Management as needed
AppServ-Asset Management
(1) The PlantPAx system is limited to two FactoryTalk Alarms and Events servers per system, with each supporting up to 10,000 alarms.
(2) Controller count per PASS or AppServ-HMI is based on approximately 1,500 I/O or 250 control strategies per controller. This is not a hard limit. The actual number of OWS/controllers supported may vary based on controller
selection, OWS configuration, and overall system loading. Use the PlantPAx System Estimator (PSE) to verify your system design. The PSE allows you to verify your application beyond these basic guidelines.
(3) Additional server or workstation may be desired to support logging of FactoryTalk Alarms and Events to a SQL database.
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PlantPAx System on an EtherNet/IP Network
The PlantPAx system is built on open industry standards, leveraging the EtherNet/IP network as its backbone, to support
seamless integration of the system components, as well as to provide connectivity to higher-level business systems. The
PlantPAx system supports the ControlNet or EtherNet/IP networks for device-level communication to deliver a business solution
with real-time results from the plant floor to the top floor.
EWS
Domain
Controller
PASS
Application Servers
Multiple OWS
ETHERNET
Logix5562
POWER
RUN
FORCE
OK
REM
PROG
ANALOG INPUT
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
RS232
BAT
RUN
ETHERNET
I/O
RXD TXD
OK
RXD TXD
OK
B
A
B
A
AC INTPUT
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 8 9 10 111213 1415
FLT 8 9 10 111213 1415
DIAGNOSTIC
DIAGNOSTIC
ETHERNET
Logix5562
POWER
ST 0 1 2 3 4 5 6 7
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
RUN
FORCE
RUN
OK
REM
PROG
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
RS232
BAT
DIAGNOSTIC
ETHERNET
I/O
RXD TXD
OK
RXD TXD
OK
B
A
B
A
ANALOG INPUT
OK
REM
PROG
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
RS232
BAT
RUN
RUN
ETHERNET
I/O
FORCE
ETHERNET
Logix5562
POWER
RXD TXD
OK
RXD TXD
OK
B
A
B
A
ANALOG INPUT
AC INTPUT
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 8 9 10 111213 1415
FLT 8 9 10 111213 1415
DIAGNOSTIC
DIAGNOSTIC
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 8 9 10 111213 1415
FLT 8 9 10 111213 1415
DIAGNOSTIC
DIAGNOSTIC
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
DIAGNOSTIC
Device-level Ring Topology
Star Topology
ETHERNET
Logix5562
POWER
RUN
FORCE
BAT
RUN
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
PROG
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
RXD TXD
OK
DIAGNOSTIC
Module
Status
Module
Status
FLT 8 9 10 111213 1415
OK
REM
ANALOG INPUT
I/O
RS232
NODE:
NODE:
NODE:
Network
Status
Network
Status
Network
Status
NODE:
NODE:
NODE:
DeviceBus
Status
Relay
Output
1734-ADNX
0
120 VAC
Input
4
1734
IA4
24VDC
Sink
Input
7
1734
OB8E
220VAC
Input
0
0
1
5 1
6 2
7 3
1734
IB8
120V
220 VAC
Output
4
5 1
6 2
3
1734
IM4
24VDC
Source
Output
4 0
1
2
3
7 3
1734
OW4
0
1
2
6 2
3
220 VAC
Input
0
0
5 1
1
2
B
NODE:
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
Network
Status
Network
Status
DeviceNet
Status
DIAGNOSTIC
Module
Status
Module
Status
Module
Status
2
3
3
1734
OA4
1734
IM4
A
PlantPAx System on a ControlNet Network
This diagram shows an example of the PlantPAx system architecture using the EtherNet/IP network for supervisory control and
the ControlNet network for the I/O communication. This example could be a centralized or distributed architecture class.
EWS
PASS
Domain
Controller
Application Servers
Multiple OWS
EtherNet/IP Network
Redundant Controllers
ControlNet Network
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Select a PlantPAx System
PlantPAx System Estimator
Rockwell Automation offers the PlantPAx
System Estimator (PSE) as part of the
Integrated Architecture Builder (IAB) tool.
The PSE lets you define your PlantPAx
system and verifies that your process
control hardware is sized properly.
The PSE creates a new workspace and
opens a wizard (shown at right) to guide
you through selecting system elements
and sizing the system based on the rules
and recommendations from PlantPAx
system characterization.
The following items will be created based
on your inputs:
• Supervisory Ethernet network with
all servers, operator, and
engineering workstations and
controller chassis
• Listing of required software
catalog numbers
• ControlNet or Ethernet network for each controller that includes all I/O requirements
• Various hardware views to support the various devices and chassis
After selecting the system elements as defined in this guide, use the PSE tool to modify their properties to create a bill of
material (BOM) in conjunction with the IAB tool. The BOM includes controllers, I/O, networks, drives, cabling and wiring, and
other devices that comprise your process automation system.
To access the IAB tool to use the PSE, see http://www.rockwellautomation.com/en/e-tools/configuration.html.
Software Release Information
The rules contained within this selection guide are based on using the following software releases:
• RSLogix™ 5000 software, version 20.x
• FactoryTalk View software, version 6.1(1)
• FactoryTalk Batch software, version 11.01
• FactoryTalk AssetCentre software, version 4.1
• FactoryTalk VantagePoint software, version 4.0
• FactoryTalk Historian software, version 3.0
(1) Performance guidelines in this document are based on using RSLinx® Enterprise software, version 5.50.04 or later.
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Select a PlantPAx System
Servers and Workstations
The supervisory layer of the PlantPAx system may include several
servers and workstations. This section explains the following
server and workstation system elements to help you define
a bill-of-material..
PASS Server
Select from the following options:
• PASS Server
• Engineering Workstation (EWS)
• Operator Workstation (OWS)
• HMI Application Server (AppServ-HMI)
• Information Management Application Server
(AppServ-Info)
• Asset Management Server (AppServ-Asset)
• Batch Management Server (AppServ-Batch)
The Process Automation System Server (PASS) is a required system element that hosts essential software components, notably
the FactoryTalk Network Directory. The directory provides central name resolution and look up services across multiple
computers for central administration of data throughout the PlantPAx system. The PASS also may be utilized as a data, HMI,
and/or alarm server.
Data servers(1) handle communication between the controllers and the servers and workstations. Data servers are limited by
capacity. The following attributes can affect data server loading:
• Communication of controllers to displays
• Number of OWS
• Communication of the controllers to data logs or historian software
• Communication of the controllers to server-based alarms
• Configured update-rate of the associated displays, alarms, data log, or historian tags
Generally, a data server can typically handle about 6 controllers, each with 1500 I/O or 250 control strategies. If the PASS server is
being used as a data server, and additional capacity is needed, you can add an HMI Application Server. See page 13 for
more information.
The HMI server stores visualization components, such as display graphics, and provides these components to Operator
Workstations (OWS) upon request. A PASS or HMI Application Server can be used to host an additional HMI server, or can be
used solely as a data and/or alarm server. If the application has data needs beyond the capability of a single server, an additional
HMI Application Server can fulfill these requirements without need of HMI server licensing.
When the PASS is used as a data server, it is also typically used as an alarm server. An alarm server is an optional component on
the PASS that provides information from the controllers and servers to all subscribing OWS stations. Alarm servers are limited to
10,000 alarms per server. When alarm servers are used, you are limited to two alarm servers per system.
Table 4 - PASS Hardware Requirements
Category
Requirement
Computer hardware
The PASS should be installed on server-class hardware. The following are sample specifications based on PlantPAx
system characterization:
• Intel Xeon Multicore processor
• 2.40 GHz CPU
• 8 GB memory
• Dual hard drives (one for application code; one for logging)
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 2008 R2 SP1 operating system, 64-bit (includes Microsoft Internet IIS with WWW service)
Additional third-party software
Antivirus software(2)
(1) FactoryTalk View software supports two types of data servers: Rockwell Automation Device servers (RSLinx Enterprise) and OPC Data servers. Our reference to the data server in this publication is for RSLinx Enterprise.
(2) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Select a PlantPAx System
The PASS requires that you purchase visualization software licenses depending on the number of displays hosted by the PASS
server. If the PASS server is not being used as an HMI server, then no license purchase is required.
Make sure to account for process displays, faceplates, navigation devices, and so forth, in your display count. For example, the
PlantPAx Library of Process objects includes 76 faceplates and help files. If all of the library objects are loaded into your
application, these faceplates and help files count against your display count license.
Table 5 - PASS Automation System Software
Category
Cat. No.(1)
Description
Visualization software
Select one of the following when the PASS is used as
an HMI server:
• 9701-VWSS000LENE
• 9701-VWSS250LENE
• 9701-VWSS100LENE
• Unlimited display license with RSLinx Enterprise software
• 250 display license with RSLinx Enterprise software
• 100 display license with RSLinx Enterprise software
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
PASS Redundancy Options
PASS servers can be configured as redundant for the following software components:
• HMI server
• Alarm server
• Data server
When redundancy is used, typically all of the above elements are made redundant; requiring duplicate hardware and
software as listed in Table 4 and Table 5. Selecting redundant data servers impacts controller memory utilization and
communication bandwidth.
For more information about configuration details, see the PlantPAx Process Automation System Reference Manual,
publication PROCES-RM001.
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Select a PlantPAx System
Engineering Workstation (EWS)
The engineering workstation (EWS) supports system configuration, application development, and maintenance functions. This
is the central location for monitoring and maintaining the systems operation. You are limited to five EWS per system.
Table 6 - Engineering Workstation Hardware Requirements
Category
Requirement
Computer hardware
The EWS should be installed on server-class hardware. The following are sample specifications based on PlantPAx
system characterization:
• Intel core I5
• 2.40 GHz CPU
• 8 GB memory
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
• Windows 7 operating system, 64-bit
• Windows 2008 R2 SP1 operating system, 64-bit
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
Table 7 - EWS Automation System Software
Category
Cat. No.(1)
Description
Visualization software
9701-VWSTENE is required for an EWS
FactoryTalk View Studio for FactoryTalk View Enterprise
Automation software
9324-RLD700NXENE is required for an EWS
RSLogix 5000 Professional Edition
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Operator Workstation (OWS)
The operator workstation (OWS) provides the graphical view and interface into the process. The workstation is a client of either
a PASS or HMI application server. The OWS supports operator interaction and is not meant to support development or
maintenance activities.
Table 8 - OWS Hardware Requirements
Category
Requirement
Computer hardware
The OWS should be installed on server-class hardware. The following are sample specifications based on PlantPAx
system characterization:
• Intel Core Duo processor
• 2.40 GHz CPU
• 4 GB memory
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 7 SP1 operating system, 64-bit
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
On an OWS, you can run multiple clients, each client requiring a license. Each client license impacts the data server loading on
the PASS and AppServ-HMI.
Table 9 - OWS Automation System Software
Category
Cat. No.(1)
Description
Visualization software
One for each separate client window on the OWS:
9701-VWSCWAENE
FactoryTalk View SE Client
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
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HMI Application Server (AppServ-HMI)
HMI application servers (AppServ-HMI) add capacity to your PlantPAx system to support large applications as well as let you
segregate your application into logical areas. For example, you can perform maintenance on one area without affecting another
area of the plant. You can add HMI application servers as needed based on operational areas in the plant or based on the
number of these components:
• Controllers
• Alarms, displays, data logs, and historian tags
• Operator interfaces
HMI servers are limited by capacity. The following attributes can affect server loading:
• Communication of controllers to displays
• Number of OWS
• Communication of the controllers to data logs or historian software
• Communication of the controllers to server-based alarms
• Configured update-rate of the associated displays, alarms, data log, or historian tags
Generally, an AppServ-HMI can typically handle about 6 controllers, each with 1500 I/O or 250 control strategies. If the
AppServ-HMI is being used as a data server, and additional capacity is needed, you can add an additional AppServ-HMI, with a
maximum of three AppServ-HMI.
The HMI server stores visualization components, such as display graphics, and provides these components to Operator
Workstations (OWS) upon request. Each additional HMI Application Server can be used to host an additional HMI server, or can
be used solely as a data and/or alarm server. If the application has data needs beyond the capability of a single server, an
additional HMI Application Server can fulfill these requirements without need of HMI server licensing.
When the AppServ-HMI is used as a data server, it is also typically used as an alarm server. An alarm server is an optional
component on the AppServ-HMI that provides information from the controllers and servers to all subscribing OWS stations.
Alarm servers are limited to 10,000 alarms per server. When alarm servers are used, you are limited to two alarm servers
per system.
Table 10 - AppServ-HMI Hardware Requirements
Category
Requirement
Computer hardware
The AppServ-HMI should be installed on server-class hardware. The following are sample specifications based on PlantPAx
system characterization:
• Intel Xeon Multicore processor
• 2.40 GHz CPU
• 8 GB memory
• Dual hard drives (one for application code; one for logging)
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 2008 R2 SP1 operating system, 64-bit (includes Microsoft Internet IIS with WWW service)
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
Table 11 - AppServ-HMI Automation System Software
Category
Cat. No.(1)
Description
Visualization software
Select one of the following when the AppServ-HMI
is used as an HMI server:
• 9701-VWSS000LENE
• 9701-VWSS250LENE
• 9701-VWSS100LENE
• Unlimited display license with RSLinx Enterprise software
• 250 display license with RSLinx Enterprise software
• 100display license with RSLinx Enterprise software
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Redundant AppServ-HMI Options
AppServ-HMI servers can be configured as redundant for the following software components:
• HMI server
• Alarm server
• Data server
When redundancy is used, typically all of the above elements are made redundant; requiring duplicate hardware and
software as listed in Table 10 and Table 11. Selecting redundant data servers impacts controller memory utilization and
communication bandwidth.
Information Management Application Server (AppServ-Info)
Information management application servers (AppServ-Info) are responsible for storing, managing process information (data
management), as well as hosting decision support tools. These decision support tools (shown in Table 13) include real-time
reports and dashboards viewable through a web browser.
The AppServ-Info server offers these features:
• Supports both data management and decision support
• Manages several different data sets flows into the server
• Supports data analysis from the server
A distributed historical-data management strategy offers localized, chassis-based, high-speed data collection and recording, as
well as site and enterprise solutions.
Table 12 - Data Management Options
Category
Requirement
Option
Time series
• High-speed, on machine data collection
• < 2500 tags
No Information Management server is required because you can use an embedded historian
module for the ControlLogix chassis (FactoryTalk Historian Machine Edition). If the historian ME
module is collecting 2500 points per second, select one of the following depending on how
long it takes for the onboard memory to become full:
• 1756-HIST1G (1 GB) = 4 hours
• 1756-HIST2G (2 GB) = 14 hours
Continuous data buffer is compatible with FactoryTalk Historian Site Edition software, which
allows the module to offload and forward that data.
• Longer term data storage
• > 2500 tags
An Information Management server is required with FactoryTalk Historian SE software, which is
a scalable process historian that provides real-time access to reliable information:
• Provides data capture, management, and analytical capabilities to support
decision-making
• Auto Discovery and Auto Configuration features reduce deployment time and lower total
cost of ownership
• Aggregate data from multiple servers
• Support a central view of data
An Information Management server is required with FactoryTalk Historian Enterprise Edition
software, which is a multi-layer data collection historian. This software supports strategies
where data historians are required at any level from Line, Plant, Site, and all the way to
Enterprise deployments, such as regions, divisions, and other sub entities of a large enterprise.
Leverages the scalability and performance in the OSIsoft PI technology.
Relational database
You can select a Microsoft SQL server database to act as the central collection point for
event-based data:
• FactoryTalk Alarms and Events data(1)
• FactoryTalk Batch data
This can be installed on an Information Management server or another server on your system.
Event based
(1) FactoryTalk View SE software version 6.10 uses Microsoft SQL Server 2008 R2 Express for the HMI Tag database. If you want to log alarm and event history, you can connect to an existing SQL server or use the SQL server
2008 R2 Express that is included on the FactoryTalk View SE software CD. For more information, see Knowledgebase Answer ID 48313 at http://www.rockwellautomation.custhelp.com.
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A decision support strategy incorporates these tools.
Table 13 - Decision Support Options
Category
Description
FactoryTalk VantagePoint and VantagePoint EMI software
An Information Management server is required to host a web-based reporting software that brings all data together into a single
decision support system:
• All manufacturing data is accessible in real-time
• Published reports, current dashboards, and real-time KPIs viewable via web browser
• Pre-configured reports, trends, and dashboards
• Published reports are always current
FactoryTalk Historian ProcessBook software
An Information Management server is required to enable ProcessBook content (Standard ProcessBook displays, SQC view, batch
view, alarm view). The content is to be hosted/displayed from within FactoryTalk View SE by using the ProcessBook Runtime.
Microsoft Excel add-ins
No Information Management server is required. Use Microsoft Excel software within the integrated environment to generate
standard reports. Build a report template once and re-use it as necessary.
Batch analysis
An Information Management server is required to create integrated, predefined reports for batch data:
• Product recipe batch records
• System trending
Alarm reports
An Information Management server is required to create integrated, predefined reports for alarm data:
• Alarm distribution
• Hourly alarm counts
• Longest alarms
• Most frequent alarms
• Standing alarms
Table 14 - Information Management Server Hardware Requirements
Category
Requirement
Computer hardware
The Information Management server must be installed on server-class hardware:
• Intel Xeon Multicore processor
• 2.40 GHz CPU
• 8 GB memory
• Dual hard drives (one for application code; one for logging)
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 2008 R2 SP1 operating system, 64-bit (includes Microsoft Internet IIS with WWW service)
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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FactoryTalk Historian and FactoryTalk VantagePoint may need to be hosted on separate information management servers
depending on the overall size of the system. The same server requirements apply if they are hosted separately.
See Knowledgebase Answer ID 62869 at http://www.rockwellautomation.custhelp.com for guidance on whether one or more
servers are required.
Table 15 - Information Management Server Software
Category
Cat. No.(1)
Description
FactoryTalk Historian software includes a FactoryTalk VantagePoint software license and one named user client. The number of users is cumulative, and can be a mixed number of named users and
concurrent users. If concurrent is selected on the PSE, a license needs to be purchased for the server based on the number of CPU’s the server has active.
Information software
Select the FactoryTalk Historian SE software tags:
• 9518-HSE250
• 9518-HSE500
• 9518-HSE1K
• 9518-HSE2K5
• 9518-HSE5K
• 9518-HSE10K
• 9518-HSE20K
• 9518-HSE50K
• 9518-HSE100K
•
•
•
•
•
•
•
•
•
250 tags
500 tags
1000 tags
2500 tags
5000 tags
10,000 tags
20,000 tags
50,000 tags
100,000 tags
Select one or more of the following for FactoryTalk
VantagePoint Client named users:
• 9521-VPNL01ENE
• 9521-VPNL03ENE
• 9521-VPNL05ENE
• 9521-VPNL010ENE
• 9521-VPNL025ENE
• 9521-VPNL050ENE
•
•
•
•
•
•
1 named user
3 named users
5 named users
10 named users
25 named users
50 named users
Select one or more of the following for FactoryTalk
VantagePoint Client concurrent users:
• 9521-VPCL01ENE
• 9521-VPCL03ENE
• 9521-VPCL05ENE
• 9521-VPCL010ENE
• 9521-VPCL025ENE
• 9521-VPCL050ENE
•
•
•
•
•
•
1 concurrent user
3 concurrent users
5 concurrent users
10 concurrent users
25 concurrent users
50 concurrent users
Select the following:
9521-VPSERVENE
VantagePoint server software
If VantagePoint is being used for concurrent users,
select one for each CPU of the hosting server:
9521-VPCPPENE
FactoryTalk VantagePoint Concurrent User CPU License (per CPU)
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
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Asset Management Server (AppServ-Asset)
An asset management server (AppServ-Asset) is an extension to the PlantPAx system that adds maintenance and plant
operations to the system. This server provides disaster recovery controller data, diagnostics, calibration, real-time monitoring, as
well as auditing equipment and network health to improve overall resource availability.
The asset management server provides a centralized system management for end field devices.
Table 16 - Asset Management Server Hardware Requirements
Category
Requirement
Computer hardware
The Asset Management server should be installed on server-class hardware:
• Intel Xeon Multicore processor
• 2.40 GHz CPU
• 8 GB memory
• Dual hard drives (one for application code; one for logging)
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 2008 R2 SP1 operating system, 64-bit (includes Microsoft Internet IIS with WWW service)
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
Table 17 - Asset Management Server Software
Category
Cat. No.(1)
Description
Asset Management software
The following is required:
9515-ASTSRVRENE
FactoryTalk AssetCentre server
If process device configuration is to be used,
select the following:
9515-ASTPRDCFENE
FactoryTalk AssetCentre process device configuration
Select one or more of the following so that the sum
of licenses is equal to or greater than the number of
assets that is to be managed by the Asset
Management server:
• 9515-ASTCAP0005E
• 9515-ASTCAP0025E
• 9515-ASTCAP0100E
• 9515-ASTCAP0500E
• 9515-ASTCAP1000E
• 9515-ASTCAP5000E
•
•
•
•
•
•
If disaster recovery is to be used, select all of
the following:
• 9515-ASTDRROKENE
• 9515-ASTDRRCENE
• 9515-ASTDRFTPENE
• Disaster recovery for Rockwell Automation
• Disaster recovery for remote computers
• Disaster recovery for generic FTP
If calibration management is to be used, the first
license is required and the remainder are optional:
• 9515-ASTCLMANENE
• 9515-ASTCLWRKENE
• 9515-ASTCLFLKENE
• 9515-ASTCLDRKENE
• 9515-ASTCLTMNENE
•
•
•
•
•
5 additional assets
25 additional assets
100 additional assets
500 additional assets
1000 additional assets
5000 additional assets
FactoryTalk AssetCentre calibration management
FactoryTalk AssetCentre calibration management remote workstation
FactoryTalk AssetCentre calibration management FLUKE documenting calibration
FactoryTalk AssetCentre calibration management Druck documenting calibration
FactoryTalk AssetCentre calibration management Trnsmtn calibration
(1) Additional licenses may be available for disaster recovery and calibration management. English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation
sales representative.
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Batch Management Server (AppServ-Batch)
The batch management server (AppServ-Batch) offers equipment-independent recipe management, batch-independent
equipment control, and regulatory compliance. System size varies from small to large and system requirements vary from
simple to complex.
Basic solutions provide capabilities for small or simple systems to use core system functions, including Logix5000™ controllers
and FactoryTalk View HMI. Generally these solutions do not need the functionality provided by server-based FactoryTalk Batch
software solutions. Comprehensive solutions provide capability for large or complex systems to use modular software
components. This includes FactoryTalk Batch software, eProcedure® software, and Material Manager software.
You need a batch server when any of the following apply for your system:
• Leverage PhaseManager™ and SFC programming (based on built-in controller-firmware functionality)
• Single-unit execution (product made in a single unit)
• Recipe management (configurable and flexible formula, procedure, and equipment)
• Data collection, reporting, and analysis (requires server for long-term storage and analysis)
• Equipment allocation and arbitration (shared resources and/or shared resources)
• Complex recipes (product recipes with loops, branches, and transitions; phases with more than four inputs
and four outputs)
• Multiple unit coordination (product is made across multiple, coordinated units)
• More than 32 recipes
• String values or numeration-required for parameter and report values
• Number of parameters or report values required by phase > 4
• Require class-based recipes
• Large system with complex routing (more than five units, may use complex routing algorithms)
• Manual and electronic work instructions (web-based instructions, embedded pictures, video)
• Material management (material container, lot, location, and property tracking.
Table 18 - Batch Management Server Hardware Requirements
Category
Requirement
Computer hardware
The Batch Management server should be installed on server-class hardware:
• Intel Xeon Multicore processor
• 2.40 GHz CPU
• 8 GB memory
• Ethernet card that supports redundant media if NIC-teaming is used
Operating system
Windows 2008 R2 SP1 operating system, 64-bit)
Additional third-party software
Antivirus software(1)
(1) Rockwell Automation has tested the use of Symantec Endpoint Protection. For more information, see Knowledgebase Answer ID 35330 at http://www.rockwellautomation.custhelp.com.
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Table 19 - Batch Management Server Software
Category
Cat. No.(1)
Description
Process software
You may have to buy multiple licenses to obtain the
desired number of batch units. For example, to
license 100 units on a single batch unit you would
buy three licenses --1 license with 10 units, 1 license
for 30 units and 1 license for 60 units:
• 9358-FTB01ENE
• 9358-FTB03ENE
• 9358-FTB10ENE
• 9358-FTB30ENE
• 9358-FTB60ENE
•
•
•
•
•
FactoryTalk Batch - 1 unit
FactoryTalk Batch - 3 units
FactoryTalk Batch - 10 units
FactoryTalk Batch - 30 units
FactoryTalk Batch - 60 units
If a back-up server is enabled on the PlantPAx
System Estimator, an additional server is added to
the BOM with an equal number of back-up server
unit licenses.:
• 9358-FTBKY01ENE
• 9358-FTBKY03ENE
• 9358-FTBKY10ENE
• 9358-FTBKY30ENE
• 9358-FTBKY60ENE
•
•
•
•
•
FactoryTalk Batch Back-up Key - 1 unit
FactoryTalk Batch Back-up Key - 3 units
FactoryTalk Batch Back-up Key - 10 units
FactoryTalk Batch Back-up Key - 30 units
FactoryTalk Batch Back-up Key - 60 units
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
Table 20 - Batch Server Software (for eProcedure software only)
Category
Cat. No.(1)
Description
Process software
eProcedure software can be licensed separately and
used in a non-batch server application. If you are
using FactoryTalk Batch, these separate licenses are
included and not required.
• 9358-EP03ENE
• 9358-EP10ENE
• 9358-EP30ENE
• 9358-EP60ENE
•
•
•
•
RSBizware™ eProcedure 3 units
RSBizwire eProcedure 10 units
RSBizwire eProcedure 30 units
RSBizwire eProcedure 60 units
If eProcedure back-up procedures are to be used,
select one of the following:
• 9358-EPBKY03ENE
• 9358-EPBKY10ENE
• 9358-EPBKY30ENE
• 9358-EPBKY60ENE
•
•
•
•
RSBizware eProcedure Back-up key 3 units
RSBizware eProcedure Back-up key 10 units
RSBizware eProcedure Back-up key 30 units
RSBizware eProcedure Back-up key 60 units
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Select a PlantPAx System
Batch High Availability Options
Warm Back-up Server
Batch high availability options depend on the
hardware and software options in the system:
NIC Teaming on Servers and Clients
• For the application server in a system
where a bump in the process cannot be
tolerated, FactoryTalk Batch software
supports a real-time, uninterrupted high
availability option that leverages Marathon
technology or VMWare virtualization.
• Standard FactoryTalk Batch software
supports a warm back-up option. The
primary server copies real-time data to the
back-up server. On failure, the process
goes to a controlled state. On restart of the
back-up server, you clear the failure and
the process resumes where it left off.
Level 3 switch with dual Ethernet
fiber connections to Level 2
fiber connections.
Redundant Controllers
Device-level Ring
• A redundant ControlLogix system with PhaseManager software provides protection so that the control platform
continues to execute during a hardware failure.
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Controller Hardware and Sizing
This section explains controller elements, how to determine I/O
count, and basic sizing guidelines.
The optimal number of controllers for the PlantPAx system depends
on the size of your application, physical layout of your plant, and the
design of your process. Consider segregating non-related process
equipment into separate controllers so that maintenance activities in
one area do not impact the operation of another area.
Select from the following options:
• Controller Sizing
• Simplex Controllers
• Redundant Controllers
• Controllers for Skid-based Equipment
Controllers also are capacity limited. This can be roughly estimated based on I/O count, but also is greatly impacted by the
design of your application. These limitations can include the amount of automation code required, the amount of information
being read by supervisory applications, and the number of alarms in your system.
Controller Sizing
The I/O count for controller sizing is often determined directly from the application P&ID or plant design. On existing systems
where only classic I/O (for example, 4…20 mA, 24V DC dry contacts, and so forth) is used, the I/O count can be determined by
the number of I/O channels available on the I/O cards.
When you have integrated smart devices, such as drives on transmitters on an EtherNet/IP network, any signal from the device
used by your control strategy is considered an I/O point.
For example, an I/O count for a system comprised with the following:
• Two 8-channel 4…20 mA input cards
• One 8-channel 4…20 mA output cards
• Two 16-channel 24V DC dry-contact input cards
• One MCC with six drives on EtherNet/IP
– Each drive provides six signals to the control strategy: speed reference, actual speed, start, stop, running, and fault
• Two Coriolis meters on PROFIBUS PA, with each meter providing three signals for flow, temperature, and density
The I/O count example has the following calculation:
4…20 mA AI
2 x 8 = 16
4…20 mA AO
1x8=
24V DC DI
2 x 16 = 32
MCC
6 x 6 = 36 (6 AI, 6 AO, 12 DI, 12 DO)
Smart instruments
2x3=
Controller I/O count
8
6 (6 AI)
___
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Select a PlantPAx System
Simplex Controllers
Non-redundant controllers are referred to as simplex controllers. There is a single CPU in the Logix chassis.
Table 21 - Simplex Controller Hardware Requirements
Category
Process controller
Cat. No.
(1) (2)
ControlLogix 1756-L71, 1756-L72, 1756-L73, 1756-L74, or 1756-L75 controller
Ethernet interface
• 1756-EN2TR, 1756-EN3TR, 1783-ETAP, 1783-ETAP1F, 1783-ETAP2F (supports device-level ring topology)
• 1756-EN2T, 1756-ENBT, 1756-EWEB, 1756-EN2F
ControlNet interface (if applicable)
• 1756-CN2, 1756-CN2R
• 1756-CNB, 1756-CNBR
(1) If environmental conditions warrant, you can use an extreme temperature controller, for example, the 1756-L74XT.
(2) For a PlantPAx system, we recommend that you use the 1756-L7x controller family. The 1756-L6x controller family is supported for existing applications. Use the PSE if sizing information is required.
Table 22 - Simplex ControlLogix Controller Sizing
Category(1)
1756-L71
User memory
2 MB
4 MB
Total I/O recommended, max
375
750
Total tags, max
15,625
31,250
Recommended control strategies, max(2)
60
Total control strategies @ 250 ms, max
60
Total control strategies @ 500 ms, max
Tags/sec delivered to data server, max(3)
1756-L72
1756-L73
1756-L74
1756-L75
8 MB
16 MB
32 MB
1500
2250
2250
62,500
112,500
112,500
125
250
450
450
125
250
250
250
60
125
250
450
450
10,000
20,000
20,000
20,000
20,000
(1) These values are maximum limits. You may not be able to achieve all of these in a single controller. For more detailed sizing, you can use the PSE.
(2) Representative control strategy (PID loop) includes 1 analog input, 1 analog output, 1 PIDE instruction, 8 logic/math instructions, and 22 alarms with PlantPAx process objects.
(3) Assumes RSLinx Enterprise software, version 5.30.00 or later, at 10 K/s per instance.
Redundant Controllers
ControlLogix controllers support redundancy on ControlNet and EtherNet/IP networks. In a redundant controller system on
PlantPAx, you need these components:
• Two 1756 chassis each set up the same with the following:
– Number of slots
– Modules in the same slots
– Redundancy firmware revisions in each module
– Two additional ControlNet or Ethernet nodes outside the redundant chassis pair
• One 1756-RM module per chassis
Table 23 - Redundant Controller Hardware Requirements
Category
Cat. No.
Process controller
ControlLogix 1756-L73, 1756-L74, or 1756-L75 controller
Redundancy module
• 1756-RM
Ethernet interface
• 1756-EN2TR, 1756-EN3TR, 1783-ETAP, 1783-ETAP1F, 1783-ETAP2F (supports device-level ring topology)
• 1756-EN2T, 1756-ENBT, 1756-EWEB, 1756-EN2F
ControlNet interface (if applicable)
• 1756-CN2, 1756-CN2R
• 1756-CNB, 1756-CNBR
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Table 24 - Redundant ControlLogix Controller Sizing
Category(1)
1756-L73
1756-L74
1756-L75
User memory
8 MB
16 MB
32 MB
Total I/O recommended, max
750
1500
2250
Total tags, max
31,250
62,500
125,000
Recommended control strategies, max(2)
125
250
450
Total control strategies @ 250 ms, max
120
120
120
Total control strategies @ 500 ms, max
125
220
220
Tags/sec delivered to data server, max(3)
20,000
20,000
20,000
(1) These values are maximum limits. You may not be able to achieve all of these in a single controller. For more detailed sizing, you can use the PSE.
(2) Representative control strategy (PID loop) includes 1 analog input, 1 analog output, 1 PIDE instruction, 8 logic/math instructions, and 22 alarms with PlantPAx process objects.
(3) Assumes RSLinx Enterprise software, version 5.30, at 10 K/s per instance.
Controllers for Skid-based Equipment
The PlantPAx process automation system is a complete, scalable system, from single controller to a fully distributed set of
equipment. You can integrate skid-based equipment into the overall system.
The CompactLogix controller platform offers a solution for skid-based equipment to be part of the overall PlantPAx system if the
application requires the following:
• Control of multiple loops for temperature, pressure, flow, or level
• Operating as a sub-system with sequencing and automation
• Controlled as part of the overall process, accepting reference inputs and delivering process variables to a
supervisory controller
.
Table 25 - Skid-based Controller Sizing
Category(1)
CompactLogix 1769-L24ER-QBFC1B
CompactLogix 1769-L35ER
User memory
0.75 MB
2.0 MB
Total I/O recommended, max
80
250
Total tags, max
4000
12,800
Recommended control strategies, max(2)
10
30
Total control strategies @ 250 ms, max
10
30
Total control strategies @ 500 ms, max
10
30
Tags/sec delivered to data server, max(3)
3000
3000
(1) These values are maximum limits. You may not be able to achieve all of these in a single controller. For more detailed sizing, you can use the PSE.
(2) Representative control strategy (PID loop) includes 1 analog input, 1 analog output, 1 PIDE instruction, 8 logic/math instructions, and 22 alarms with PlantPAx process objects.
(3) Assumes RSLinx Enterprise software, version 5.30, at 10 K/s per instance.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Notes:
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I/O Components
I/O components connect process instrumentation and
field devices to the PlantPAx system to provide real-time data.
I/O Product Family and Communication
Interfaces
Select from the following options:
• I/O Product Family and Communication Interfaces
• Redundant I/O
• Process Network I/O
The PlantPAx system supports several families of I/O, from controller chassis-based (1756 and 1769) to smaller, distributed I/O
(1734 and 1794).
Table 26 - I/O Communication Interfaces
Category
Family
Cat. No.
In-cabinet I/O modules
1734 POINT I/O™
• 1734-AENT, 1734-AENTR EtherNet/IP adapter
• 1734-ACNR ControlNet adapter (redundant)
• 1734-ADN, 1734-ADNX, 1734-PDN DeviceNet adapter
1790 CompactBlock™ LDX I/O
Built-in DeviceNet connectivity
1791D CompactBlock I/O
Built-in DeviceNet connectivity
1794 FLEX™ I/O(1)
• 1794-AENT EtherNet/IP adapter
• 1794-ACN15, 1794-ACNR15, 1794-ACN15K, 1794-ACNR15K ControlNet adapter
• 1794-ADN DeviceNet adapter
1797 FLEX Ex™ intrinsically safe I/O
• 1797-ACNR15 ControlNet adapter
• 1794 adapter with 1797-BIC isolator and 1797-CEC connector
1732 ArmorBlock® I/O
Built-in EtherNet/IP or DeviceNet connectivity
1738 ArmorPOINT® I/O
• 1738-AENT EtherNet/IP adapter
• 1738-ACNR ControlNet adapter
• 1738-ADN12, 1738-ADN18, 1738-ADN18P, 1738-ADNX DeviceNet adapter
1799 Embedded I/O
Built-in DeviceNet connectivity
Chassis-based I/O modules
1756 ControlLogix I/O
• 1756-EN2T, 1756-EN2TR, 1756-EN2F, 1756-ENBT EtherNet/IP module
• 1756-CN2, 1756-CN2R, 1756-CNB, 1756-CNBR ControlNet module
• 1756-DNB module
Variable frequency drives
PowerFlex® drives
Some drives offer built-in EtherNet/IP connectivity; others require separate adapter:
• 20-COMM-E EtherNet/IP adapter
• 20-COMM-C, 20-COMM-Q ControlNet adapter
• 20-COMM-D DeviceNet adapter
Soft motor starters
150 SMC™ smart motor controller
Built-in DeviceNet connectivity
Overload relays
193 E1 overload relays
592 E3 overload relays
Built-in EtherNet/IP or DeviceNet connectivity
Motor control centers(2)
CENTERLINE® 2100
CENTERLINE 2500
• Built-in EtherNet/IP connectivity or via 1788-EN2DN linking device
• Built-in DeviceNet connectivity
• ControlNet connectivity via 1788-CN2DN linking device
Condition monitoring
1440 XM® intelligent I/O modules
• Built-in DeviceNet connectivity
• ControlNet connectivity via 1440-ACNR ControlNet adapter with 1440-DYN02-01RJ
module only
On-machine I/O modules
(1) If environmental conditions warrant, you can use extreme temperature FLEX I/O modules.
(2) Networked motor control center devices can be used in place of standard I/O modules (digital and analog outputs).
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
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Select a PlantPAx System
For more information on the communication and usage based on the selected I/O family, refer to the following
Rockwell Automation literature:
• ControlLogix Selection Guide, publication 1756-SG001
• CompactLogix Selection Guide, publication 1769-SG001
• FLEX I/O and FLEX Ex Selection Guide, publication 1794-SG002
• POINT I/O Selection Guide, publication 1734-SG001
Table 27 shows some of the modules that you can add to the Controller Organizer in RSLogix 5000 software when the controller
is in Run mode.
Table 27 - Online Addition of Module and Connection Types
Module Type and
Communication Method
In Local Chassis
Offline
Runtime
In Remote Chassis via a ControlNet Network
In Remote Chassis via a
EtherNet/IP Network
Offline
Offline
Runtime
Runtime
Scheduled
Unscheduled
Scheduled
Unscheduled
Motion - direct
Yes
No
N/A
N/A
N/A
N/A
N/A
N/A
Digital - direct
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Digital-rack-optimized
N/A
N/A
Yes
No
Yes
No
Yes
Yes
Analog - direct
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Generic third-party - direct
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
1756-DNB
Yes
No
Yes
No
No
No
Yes
Yes
1756-DHRIO
Yes
No
Yes
No
No
No
Yes
Yes
1756-CNx - no connection
Yes
Yes
Yes
Yes
No
Yes
N/A
N/A
1756-CNx - rack-optimized
N/A
N/A
Yes
N/A
N/A
N/A
N/A
N/A
Generic ControlNet
third-party -direct
N/A
N/A
Yes
Yes
No
Yes
N/A
N/A
1788-EN2FF linking device
N/A
N/A
N/A
N/A
N/A
N/A
Yes
Yes
1788-CN2FF linking device
N/A
N/A
Yes
Yes
No
Yes
N/A
N/A
1788-EN2PAR
N/A
N/A
N/A
N/A
N/A
N/A
Yes
Yes
1788-CN2PAR
N/A
N/A
Yes
Yes
No
Yes
N/A
N/A
1715 Redundant I/O
No
No
No
No
No
No
Yes
Yes
1756-ENx - no connection
Yes
Yes
N/A
N/A
N/A
N/A
Yes
Yes
1756-ENx - rack-optimized
N/A
N/A
N/A
N/A
N/A
N/A
Yes
Yes
Generic EtherNet/IP
third-party - direct
N/A
N/A
N/A
N/A
N/A
N/A
Yes
Yes
26
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Redundant I/O
The 1715 redundant I/O system lets a ControlLogix controller communicate to a remote, redundant I/O chassis over an
EtherNet/IP network. The 1715 redundant I/O system provides fault tolerance and redundancy for critical processes by using a
redundant adapter pair and multiple I/O modules that have enhanced diagnostics.
Redundant Controllers
Device-level Ring
EtherNet/IP Network
Simplex I/O Modules
Redundant I/O Modules
The 1715 I/O system supports as many as 24 I/O modules per set of adapters.
Table 28 - 1715 I/O Modules
Cat. No.
Description
1715-AENTR
EtherNet/IP adapter
1715-IB16D
16 point, 24V DC diagnostic input module
1715-OB8DE
8 point, 24V DC diagnostic output module, electronically fused
1715-IF16
16 channel, 4…20 mA, current analog input module
1715-OF8I
8 channel, 4…20 mA, current analog output module, isolated
For more information, see the following:
• Redundant I/O System User Manual, publication 1715-UM001
• Fault tolerant configurations, page 41
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
27
Select a PlantPAx System
Process Network I/O
Use of smart instrumentation has increased in the marketplace. This enables the PlantPAx system to
leverage the devices’ improved data and control capabilities. In a PlantPAx system, the controllers
are connected to the field devices via field device components and communicate through the
EtherNet/IP, DeviceNet, ControlNet, FOUNDATION Fieldbus, and PROFIBUS PA networks or by using
the HART protocol.
Many I/O and field device products are available via the Encompass third-party product referencing
program. To sort and filter products from best-in-industry suppliers in your region,
see http://www.rockwellautomation.com/encompass.
EtherNet/IP Devices
EtherNet/IP Network
HART
Devices
PROFIBUS PA Network
In a PlantPAx system, the EtherNet/IP network provides the
communication backbone for the supervisory network for the
workstations, servers, and the controllers. The EtherNet/IP network also
supports controller downlinks and connections to remote I/O and field
device interfaces. EtherNet/IP is supported by the Open Device Vendors
Association (ODVA).
Field instruments that support a direct connection to EtherNet/IP
networks include the following:
• Endress+Hauser, Promass 80 and Promass 83 Coriolis flowmeters
for liquid and gas flows
• Endress+Hauser, Promag 53 electromagnetic flowmeter for
conductive liquids
Table 29 - EtherNet/IP Interface
Category
Cat. No.
Description
ControlLogix controller interface
1756-EN2T, 1756-EN2TR,1756-EN2F
1756-ENBT
1756-EWEB
ControlLogix EtherNet/IP scanner.
1788-EN2FFR
EtherNet/IP to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION Fieldbus
networks and redundant media.
1788-EN2PAR
EtherNet/IP to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media and
DLR capable Ethernet network.
28
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
ControlNet Devices
The ControlNet network is an open, control network for
real-time, high-throughput applications that uses the
Common Industrial Protocol (CIP) to combine the functionality
of an I/O network and a peer-to-peer network, providing highspeed performance for both functions. ControlNet is supported
by the Open Device Vendors Association (ODVA).
In a PlantPAx system, the ControlNet network supports
controller downlinks and connections to remote I/O and field
device interface
ControlNet Network
PROFIBUS PA
Network
HART Devices
Table 30 - ControlNet Interface
Category
Cat. No.
Description
ControlLogix controller interface
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
ControlLogix ControlNet scanner.
1788-CN2FFR
ControlNet to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION Fieldbus
networks. Compatible with ControlLogix redundancy and redundant ControlNet media.
1788-CN2PAR
ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media and
redundant ControlNet media.
DeviceNet Devices
DeviceNet Network
PowerFlex
Drives
CENTERLINE
Motor Control
Center
The DeviceNet network is an open, device-level network that
provides connections between simple industrial devices (such as
sensors and actuators) and higher-level devices (such as PLC
controllers and computers). The DeviceNet network uses the proven
Common Industrial Protocol (CIP) to provide the control,
configuration, and data collection capabilities for industrial devices.
DeviceNet is supported by the Open Device Vendors Association
(ODVA).
In a PlantPAx system, the DeviceNet network connects networked
control devices.
Table 31 - DeviceNet Interface
Category
Cat. No.
Description
ControlLogix controller interface
1756-DNB
ControlLogix DeviceNet scanner
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
29
Select a PlantPAx System
HART Devices
HART is an open protocol designed to connect analog devices. The
PlantPAx system interfaces both directly and via remote I/O modules to
provide a single termination point to gather analog process variables and
the additional HART digital data.
HART device integration tools include the following:
• Pre-engineered controller code with Add-On Instructions that
provide two-way exchange of data between faceplates and the
ControlLogix controller
• Pre-configured operator faceplates that provide visualization of
instruments connected to the network interface
• Integration documentation that describes the implementation, at
http://www.rockwellautomation.com/solutions/process/
integrationdocs.html
Controller Network
HART Devices
.
Table 32 - HART Interface
Category
Cat. No.
Description
Chassis-based I/O modules
1756-IF8H, 1756-OF8H
1756-IF16H
ControlLogix analog I/O modules with the following:
• Standard profiles in RSLogix 5000 software
• DTMs
MVI56-HART
ProSoft Technology, HART multi-drop communication interface module for ControlLogix
system for use in FactoryTalk AssetCentre Process Device Configuration or other asset
management system based on FDT Technology (IEC-62453, ISA103).
1734-sc-IF4H
Spectrum Controls, analog input module with HART for the POINT I/O system.
1769-sc-IF4IH, 1769-sc-OF4IH
Spectrum Controls, analog, isolated input and output modules with HART
for Compact I/O™ modules.
1794-IE8H, 1794-OE8H
1794-IF8IH, 1794-OF8IH
1797-IE8H, 1797-OE8H
FLEX analog I/O and FLEX Ex analog I/O modules with the following:
• Standard profiles in RSLogix 5000 software
• DTMs
Multiplexers/gateways
Wireless HART adapter
Pepperl+Fuchs, wireless HART adapter.
See the Encompass website for Pepperl+Fuchs product offerings.
Network configuration
Handheld device
Endress+Hauser, handheld configuration and diagnostic device.
See the Encompass website for Endress+Hauser product offerings.
Distributed I/O modules
30
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
FOUNDATION Fieldbus Devices
The FOUNDATION Fieldbus network is a protocol designed for robust, distributed control of process control applications.
Devices connected by a FOUNDATION Fieldbus network can be used for sophisticated process control with seamless data
distribution from the H1 device-level network.
PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNet/IP and ControlNet linking devices as
shown in the examples below. Other configurations are available for simple and redundant topologies.
EtherNet/IP Linear
EtherNet/IP Device Level Ring
Redundant ControlNet
EtherNet/IP Network
EtherNet/IP Network
1788-EN2FFR
Linking Device
ControlNet Network
Redundant ControlNet
1788-CN2FFR Linking Devices
1788-EN2FFR Linking Devices
1788-FBJB4 Junction Boxes
1788-FBJB6
Junction Box
FF Field Devices
FF Field Devices
FF Field Devices
Table 33 - FOUNDATION Fieldbus Interface
Category
Cat. No.
Description
EtherNet/IP interface
1788-EN2FFR
Bridge from an Ethernet network to an H1 network. Supports redundant media and
DLR capable Ethernet network.
ControlNet interface
1788-CN2FFR
Bridge from a ControlNet network to an H1 network; compatible with ControlLogix
redundancy and redundant ControlNet media.
FOUNDATION Fieldbus network components
Power conditioning
Both linking devices have built-in power conditioning.
1788-FBJB4R
Intelligent junction box supports redundancy, includes four drop ports and four trunk ports.
1788-FBJB6
Intelligent junction box with six drop ports and two trunk ports.
Terminators
Pepperl+Fuchs, FOUNDATION Fieldbus components, such as valve couplers, surge
protectors, terminators, distributors, and power products.
See the Encompass website for Pepperl+Fuchs product offerings.
Segment protection
Protects against device or line faults with short- and open-circuit protection.
FOUNDATION Fieldbus device integration tools include the following:
• Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates
and the ControlLogix controller
• Pre-configured operator faceplates that provide visualization of instruments connected to the network interface
• Field Device Tool/Device Type Manager (FDT/DTM) technology allows access to field device configuration and
diagnostics via FDT Frames, such as FactoryTalk AssetCentre. In addition, the Rockwell Automation FDT ThinFrame
(read only) can be launched via the Add-On Profile providing access to each field device status and extended diagnostics
• Integration documentation that describes the implementation,
at http://www.rockwellautomation.com/solutions/process/integrationdocs.html
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
31
Select a PlantPAx System
PROFIBUS PA Devices
The PROFIBUS PA network is the PROFIBUS solution for process automation. The PROFIBUS PA network connects automation
systems and process control systems with field devices such as flow, level, pressure, and temperature transmitters.
PlantPAx systems communicate with PROFIBUS PA fieldbus devices through EtherNet/IP and ControlNet linking devices as
shown in the examples below. Other configurations are available for simple and redundant topologies.
EtherNet/IP Linear
EtherNet/IP Device Level Ring
Redundant ControlNet
EtherNet/IP Network
EtherNet/IP Network
ControlNet Network
1788-EN2PAR
Linking Device
1788-CN2PAR Linking Devices
1788-FBJB4R Junction Boxes
1788-FBJB6
Junction Box
PROFIBUS PA Devices
PROFIBUS PA Devices
PROFIBUS PA Devices
Table 34 - PROFIBUS PA Interface
Category
Cat. No.
Description
PROFIBUS interface
1788-EN2PAR
EtherNet/IP to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media and
DLR capable Ethernet network.
1788-CN2PAR
ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media and
redundant ControlNet media.
Power conditioning
Both linking devices have built-in power conditioning.
1788-FBJB4R
Intelligent junction box supports redundancy, includes four drop ports and four trunk ports.
1788-FBJB6
Intelligent junction box with six drop ports and two trunk ports.
Terminators
Pepperl+Fuchs, PROFIBUS components, such as valve couplers, surge protectors,
terminators, distributors, and power products.
See the Encompass website for Pepperl+Fuchs product offerings.
Segment protection
Protects against device or line faults with short- and open-circuit protection.
PROFIBUS network components
PROFIBUS PA device integration tools include the following:
• Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates
and the ControlLogix controller
• Pre-configured operator faceplates that provide visualization of instruments connected to the network interface
• Field Device Tool/Device Type Manager (FDT/DTM) technology allows access to field device configuration and
diagnostics via FDT Frames, such as FactoryTalk AssetCentre. In addition, the Rockwell Automation FDT ThinFrame
(read only) can be launched via the Add-On Profile providing access to each field device status and extended diagnostics
• Integration documentation that describes the implementation,
at http://www.rockwellautomation.com/solutions/process/integrationdocs.html
32
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Network Infrastructure
It’s important to consider your topology when weighing redundancy
options for EtherNet/IP and ControlNet networks. This section
provides basic information on network infrastructure.
The PlantPAx system infrastructure is built on open industry
standards to support seamless integration of the system
components, as well as to provide connectivity to higher-level
business systems. The system leverages best-of-breed technology
partners to deliver maximum value without relying on proprietary
hardware and software.
Select from the following options:
• Domain Controller
• Redundant Network Topologies
• Ethernet Switches
• Virtualization
Domain Controller
A domain controller manages access to network resources (such as applications and printers) for a group of users. Domain
authentication, whether it’s an existing domain or a new one, is recommended.
Follow these guidelines for the domain controller:
• A domain controller is required if there are 10 or more workstations or servers.
• The domain controllers are separate computers. Do not load any application software on a domain controller. Load all
system application software on the other computers, such as the PASS, application server, OWS, and EWS.
• Microsoft support does not recommend running applications on a domain controller, and certainly not applications that
require more than Authenticated User privileges to run.
• The domain controllers must be local to the system workstations and servers (within the local firewall) and not remote to
the system.
For redundancy purposes, we recommend that you use at least two domain controllers in the domain. These domain
controllers will replicate automatically to provide high availability and an online configuration backup.
For more domain recommendations, see the PlantPAx Process Automation System Reference Manual,
publication PROCES-RM001.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
33
Select a PlantPAx System
Redundant Network Topologies
Ethernet networks have active infrastructures that rely on switches for managing traffic. You can design a network with
individual switch devices and devices that have embedded switch technology.
Table 35 - Redundant Supervisory Network
Topology
Description
Redundant Star
Recommended for supervisory networks.
A redundant star topology is essentially where every Layer 2 access switch has dual connections to a
Layer 3 distribution switch. Devices are connected to the Layer 2 switches.
Advantages
Disadvantages
• Resiliency from multiple connection failures
• Additional wiring and ports required
• Faster convergence to connection loss
• Additional configuration complexity
• Consistent number of hops provide predictable
and consistent performance
• Fewer bottlenecks
Switch ring(1)
A switch ring network is a single-fault tolerant ring network that connects Layer 2 switches to a Layer 3
distribution switch.
Advantages
Disadvantages
• Ability to survive a single point of failure or a
device being powered down on the ring
• Additional configuration complexity
• Simplified cabling
• Variable number of hops can make performance
difficult to predict
• Ability to cover long distances with 100 m
allowed between each copper segment
• Longer convergence times
(1) Not characterized with PlantPAx system testing, but assumed a valid configuration.
Additional Ethernet features that support high availability include these advanced network resiliency and convergence
techniques:
• EtherChannel and Link Aggregation Control Protocol (LACP) provide additional bandwidth between two devices by
aggregating multiple Ethernet connections into a higher bandwidth virtual connection. These protocols quickly recover
from the loss of one or more channel members.
• Flex Links is a Cisco-proprietary resiliency protocol that is for use in redundant star networks. This protocol connects an
access switch to a distribution switch.
34
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Table 36 - Redundant I/O Network
Device-level ring (DLR)
Recommended for control and I/O networks.
A DLR network is a single-fault tolerant ring network intended for the interconnection of automation
devices. This topology has switches embedded into the end devices themselves; no additional switches are
required.
The DLR topology does require additional effort to set up and use as compared to a linear network.
TXD
15
BAT
RUN
FLT
OK
REM
PROG
RXD
OK
B
A
8 9 10 11121314
DIAGNOSTIC
DIAGNOSTIC
Advantages
Disadvantages
• Ability to survive a single point of failure or a
device being powered down on the ring
• Supervisor-node configuration required
• Simplified cabling
• Variable number of hops can make performance
difficult to predict
• Ability to cover long distances
with 100 m allowed between each copper
segment
Module
Status
Module
Status
NODE:
NODE:
Module
Status
Module
Status
Module
Status
NODE:
NODE:
NODE:
• Very fast network convergence
Network
Status
Network
Status
Network
Status
NODE:
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
Network
Status
Network
Status
DeviceNet
Status
NODE:
DeviceBus
Status
Relay
Output
1734-ADNX
0
120 VAC
Input
4
3
1734
OW4
6
2
7
3
0
1
6 2
3
1734
IM4
7 3
1734
IB8
120V
220 VAC
Output
4
5 1
2
3
24VDC
Source
Output
4 0
1
2
1734
IA4
24VDC
Sink
Input
220 VAC
Input
0
0
5 1
1
2
1734
OB8E
1
2
7
3
220VAC
Input
0
0
5
6
1
2
3
1734
OA4
1734
IM4
Redundant ControlNet media
ControlLogix
1756-C2NR
• Additional configuration complexity
A ControlNet network supports the option of redundant media. For information on ControlNet media, see
ControlNet Media System Components List, AG-PA002.
Node
Redundant Media
Node
Advantages
Disadvantages
• ControlNet network supports a variety of
topologies, including trunkline/dropline, star,
tree, and ring.
• An additional network topology, cabling, and
components for adding devices to the
EtherNet/IP network.
• Deterministic, real-time control network that
provides high-speed transport of both
time-critical I/O and messaging data
• Repeaters are required to create other
topologies with additional distance
between nodes.
• Network unaffected by devices being connected
or disconnected from the network.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
35
Select a PlantPAx System
Ethernet Switches
Infrastructure components that integrate enterprise, manufacturing, and plant-floor environments include Ethernet switches.
Table 37 - Ethernet Switches
If
Then
Recommended Media
• Supervisory
• Routing information to other networks
Layer 3 switches
• Stratix 8300™
• Cisco Catalyst 3560G or equivalent
• Cisco Catalyst 3750 or equivalent
Fiber(1)
• Connecting control hardware, sensors, and workstations
• Isolated networks
Layer 2 switches
• Stratix 8000™
• Stratix 6000™
• Cisco Catalyst 2960G or equivalent
1585-series copper media
High availability at switch level
Layer 3 switch
• Stackwise 3750G or equivalent
Fiber(1)
(1) For uplink cables between Layer 2-3, fiber is recommended for 1 GB connectivity.
Virtualization
Virtualization breaks the dependency between operating system and physical hardware, allowing multiple virtual machines to
run different operating systems and applications from varying locations on the same server. You also have the ability to upgrade
hardware without replacing the operating system on server or workstation system elements.
If you are considering virtualization, you do not purchase specific server or workstation hardware for the system elements being
virtualized. You need only the servers, storage, and network hardware for your virtual infrastructure. We suggest that you
contact Network and Support Services from Rockwell Automation to assist you.
36
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Advanced Process Control
Advanced Process Control (APC) is an umbrella term that covers a
wide range of control technologies from simple regulatory loops to
complex multi-unit optimizations. Depending on the context,
anything more sophisticated than a simple PID loop can be
considered APC.
Select from the following options:
• Regulatory Control Options
• Supervisory Control Options
The PlantPAx portfolio for APC provides a comprehensive set of tools and solutions to optimize performance. This scalable
framework lets you add the tools you need:
• Control regulatory loops, individual process units, and plant operations
• Use modeling techniques to achieve more accurate and robust models
Pavilion 8 Dynamic Software
APC Function Blocks
and Fuzzy Designer
Software
Standard Logix5000
Instructions
Regulatory
Control
Model Builder Software
Inferential Sensor
Model Predictive Control
and Real Time Optimization
Advanced
Regulatory
Control
a
sing V
Increa
lue
As you add advanced process control technologies, the technologies deliver more value while becoming more complex.
There are two main categories for APC technologies: regulatory control and supervisory control:
• Regulatory control focuses on the process variables (levels, flows, temperatures, pressures, and so forth) and is designed
to improve poorly performing loops and automate loops that are typically run in manual by the operator. They include
techniques such as ratio, feed-forward, cascade, and decoupling control and can be used to compensate for process
dead-time and simple process coupling and nonlinearities that a PID loop cannot handle.
• Supervisory control focuses on the product being manufactured (cement, polyethylene, ethanol, paper, and so forth)
and is designed to control the various product specifications and parameters that determine whether the product is
marketable. Parameters include impurity percentage, moisture content, color, density, and fineness. Instead of making
direct control outputs, supervisory controls generate setpoints for lower-level regulatory controls, thus good regulatory
control performance is an essential first step before implementing supervisory control.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
37
Select a PlantPAx System
Regulatory Control Options
APC function blocks can be used in place of PID instructions for loops with long dead-times and interacting loops. The
APC function blocks run on the EWS and require RSLogix 5000 software.
Table 38 - APC Function Block Descriptions
APC Instruction
Description
Internal model control (IMC)
Controls a single process variable (such as a temperature or pressure) with a single control variable (such as a valve position
or pump speed).
Compares actual process error against error calculated by an internal first order lag plus dead-time model.
Suitable for long dead-time processes which are difficult to control with standard PID loops.
Coordinated control (CC)
Controls a single process variable with up to three control variables.
It is good for situations where multiple outputs are available for control, and costs need to be minimized or for situations
where additional process information is available for feed-forward control.
Target values and priorities for outputs are used to optimize your process.
Modular multivariable control (MMC)
Controls two process variables with up to three control variables.
It is good for situations where there is significant interaction between the various control variables and process variables.
Table 39 - APC Software
Category
Cat. No.(1)
Description
Automation software
• 9324-RLDAPCENE for first controller
• 9324-RLDAPCCLENE for subsequent controllers
• RSLogix 5000 APC Design License
• RSLogix 5000 APC Run-time License
(1) Different languages are available, but you must contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
Fuzzy Designer
Fuzzy logic is useful when a well-tuned PID controller does not provide desired response, but an expert knows from experience
how to modify controller settings on-the-fly. Fuzzy Designer software lets you do the following:
• Convert expert know-how into a control solution
• Generate an Add-On Instruction for Logix5000 applications
Table 40 - Fuzzy Designer Software
Category
Cat. No.(1)
Description
Automation software
• 9324-RLDFZYENE
• 9324-RLD700NXENE
• Fuzzy Designer for RSLogix 5000 software
• RSLogix 5000 Professional Edition
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
38
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Soft Sensors
Soft sensors built with PlantPAx ModelBuilder software can automatically predict product quality parameters in real-time and
provide backup or an alternative to analyzers to generate feedback for mission-critical control systems. The software, which runs
on the EWS, also includes the following:
• ModelBuilder provides offline data analysis and modeling
• SoftSensor Designer converts models to Add-On Instructions
Table 41 - PlantPAx ModelBuilder Software
Category
Cat. No.(1)
Description
Automation software
Select one or more of the following:
• 9529-PPMDBENE
• 9529-PPMSBENE
• 9529-PPMSSENE
• PlantPAx ModelBuilder
• PlantPAx ModelBuilder and SoftSensor Designer
• Soft Sensor Designer
(1) English version is listed. Different languages are available by contacting your local Allen-Bradley distributor or Rockwell Automation sales representative.
Supervisory Control Options
The most common supervisory control
technique is Model Predictive Control (MPC),
which can handle large multivariable processes
and control these product parameters while
simultaneously optimizing the production
process through maximizing rates and yields,
reducing raw material usage, minimizing
energy, and so forth.
Console
Soft
Sensors
Controller
Metrics
115
92
64
70
50
39
33
25
13
The Pavilion8 software platform from Pavilion
Technologies, a Rockwell Automation company,
Dynamic MPC
is a modular software platform that includes
modules to control, analyze, monitor, visualize,
warehouse, and integrate information. MPC
technology is an intelligence layer on top of
SCADA/HMI
Control
MES
Custom
Plant
SPC/SQC
Laboratory
Maintenance
basic automation systems that continuously
Services
Systems
Systems
Database
Historians
Systems
Systems
Systems
drives the plant to achieve multiple business
objectives—cost reductions, decreased emissions, consistent quality, and production increases—every production minute.
6
10
10
MPC technology continuously assesses current and predicted operational data, compares them to desired results, and
computes new control targets to reduce in-process variability and improve process performance.
Use the Pavilion platform within a PlantPAx system to add model predictive control, environmental performance management,
and production performance management.
For purchase information, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
39
Select a PlantPAx System
Notes:
40
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Select a PlantPAx System
Process Safety Systems
With the combination of products from Rockwell Automation and
ICS Triplex, a Rockwell Automation company, the PlantPAx system
supports expanded process safety offerings that provide a high-level
of fault tolerance, safety, and critical process control.
Select from the following options:
• ControlLogix SIL 1 and SIL 2 Systems
• ICS Triplex SIL 2 and SIL 3 Systems
• SIL-rated Instruments
Safety System
Development Workstation
(IsaGraph for TMR)
(RSLogix 5000 for ControlLogix)
SIL 2 Controller for Fail Safe
or Fault Tolerance
TMR SIL 3 Safety
Controller and I/O
Scalable Controller for SIL 2-3 and SIL
Fail Safe and Fault Tolerance
Select safety equipment based on Safety Integrity Level (SIL) requirements. For example, if your system needs to continue
running under a fault condition, you require process safety, such as an ICS Triplex system. If a fault occurs and you want to shut
down safely, you select machine safety, such as a GuardLogix® system.
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
41
Select a PlantPAx System
ControlLogix SIL 1 and SIL 2 Systems
Safe, reliable systems safeguard people, property, the environment, and reputations. SIL certification makes it simpler, easier,
and less expensive to meet growing standards compliance requirements worldwide.
Common ControlLogix components and tools help customers lower lifecycle costs for both process control and for separate,
independent safety instrumentation. The SIL 2 certification of ControlLogix products assures the suitability of ControlLogix
components, development tools, networks, and databases for use in safety applications up to and including SIL 2.
Specific hardware, firmware revisions, and software versions meet SIL certifications. To make sure you have the correct
equipment, see the Using ControlLogix in SIL 2 Application Safety Reference Manual, publication 1756-RM001.
ICS Triplex SIL 2 and SIL 3 Systems
ICS Triplex systems use a triple modular redundant (TMR) architecture. Triple redundancy eliminates the possibility of any single
component failure causing a spurious or false trip. ICS Triplex integration with PlantPAx systems includes OPC connectivity to
FactoryTalk applications and CIP connectivity including profile support in RSLogix 5000 software.
Both the Trusted and AADvance systems share a common Ethernet/IP network within a PlantPAx system. In addition, the
AAdvance system supports the CIP producer/consumer communication protocol.
Table 42 - ICS Triplex Products
Category
Description
Trusted system
Trusted technology uses 3-3-2-0 fault-tolerant control to virtually eliminate spurious trips. Triple modular redundancy (TMR) uses
majority voting to identify a source of failure. Available with OPC or CIP integration.
AADvance system
The AADvance technology is the following:
• Configurable for SIL 2 and SIL 3
• Scalable redundancy for fault tolerance
• Simplex, duplex, or triplex configuration
ICS Triplex technology is available only as a complete system from ICS Triplex, a Rockwell Automation company. For information,
contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
SIL-rated Instruments
A number of SIL-rated instruments are available in the Process market. Rockwell automation provides premier integration
between ControlLogix systems and these Endress+Hauser SIL-rated instruments. Premier integration includes integration
documents and application libraries. See the Rockwell Automation Knowledgebase Answer ID 62366 at
http://rockwellautomation.custhelp.com.
Table 43 - SIL-rated Instruments
Category
Description
SIL 2 Endress+Hauser instruments
•
•
•
•
•
SIL 3 Endress+Hauser instruments
• Cerabar S PMC71 pressure
• Deltabar S PMD75 differential pressure
42
Promass 83 Coriolis mass flow
Prowirl 73 Vortex flow
Levelflex M FMP40 guided radar level
Micropilot M FMR240 radar level
iTEMP TMT182 temperature transmitter
Rockwell Automation Publication PROCES-SG001E-EN-P - July 2012
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and
application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the
best use of these tools.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnectSM
support programs. For more information, contact your local distributor or Rockwell Automation representative,
or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual.
You can contact Customer Support for initial help in getting your product up and running.
United States or Canada
1.440.646.3434
Outside United States or
Canada
Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact
your local Rockwell Automation representative.
New Product Satisfaction Return
Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility.
However, if your product is not functioning and needs to be returned, follow these procedures.
United States
Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain
one) to your distributor to complete the return process.
Outside United States
Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document,
complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
Allen-Bradley, Rockwell Software, Rockwell Automation, LISTEN. THINK. SOLVE., PlantPAx, ControlLogix, CompactLogix, GuardLogix, FactoryTalk, Integrated Architecture, CENTERLINE, RSLinx, Logix5000,
RSLogix, ArmorBlock, ArmorPOINT, CompactBlock, FLEX Ex, FLEX, PowerFlex, PhaseManager, Encompass, POINT I/O, Stratix 6000, Stratix 8000, Stratix 8300, eProcedure, RSBizware, SMC, Compact I/O, XM, and
TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400
Publication PROCES-SG001E-EN-P - July 2012 44
Supersedes Publication PROCES-SG001D-EN-P - December 2011
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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