Dcs

PlantPAx Process Automation System
Selection Guide
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell
Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING
Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury or death, property damage,
or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence
SHOCK HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.
BURN HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.
3Publication PROCES-SG001B-EN-P - September 2009 3
Table of Contents
Chapter 1
PlantPAx Process Automation
System Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Architecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Independent Class Architecture Example. . . . . . . . . . . . . . . . . . . . . . . 10
Centralized Class Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 12
Distributed Class Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 14
Recommended Architecture Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 2
PlantPAx Core System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Core Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Core Servers and Workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engineering Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3
PlantPAx Field Device Integration
and Asset Management
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EtherNet/IP Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ControlNet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DeviceNet Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
HART Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FOUNDATION Fieldbus Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PROFIBUS PA Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Asset Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 4
PlantPAx Batch Management and
Control
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Basic Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Comprehensive Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . 41
Material Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 5
PlantPAx Process Information Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Information Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 6
PlantPAx Plantwide Optimization Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 7
PlantPAx Critical Process Control
and Safety Systems
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
High Availability Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ControlLogix SIL 1 and SIL 2 Systems. . . . . . . . . . . . . . . . . . . . . . . . . 55
ICS Triplex SIL 2 and SIL 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Publication PROCES-SG001B-EN-P - September 2009
Table of Contents
Chapter 8
PlantPAx Infrastructure Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Domain Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Ethernet Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
System Software and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 9
PlantPAx Migration Tools Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Migration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 1
PlantPAx Process Automation System
Overview
Introduction
The PlantPAx system represents the Rockwell Automation culmination of
significant investment in automation technology in the process industry. The
PlantPAx system unifies core Integrated Architecture process automation
capabilities and technologies with those of market leading partners, such as
OSIsoft, Endress+Hauser, and acquisitions like Incuity, Pavilion Technologies,
ICS Triplex, XiAn Hengsheng, and ProsCon, under a common systems and
solutions umbrella to provide a scalable, open, and cost-effective process
solution.
Core System
Pleld Devlce |ntegratlon / Asset
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Crltlcal Process Control
& Process Safety

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Chapter 1 PlantPAx Process Automation System Overview
The PlantPAx system focuses on these main areas.
PlantPAx System Focus Areas
Focus Area Description
Core system The PlantPAx core system consists of:
engineering development environment.
system-wide visualization.
multi-disciplined process control.
Size the core for small, single-unit systems or add to the core for large, highly-distributed, multi-area
applications. Based on Integrated Architecture automation products, the core system can be
extended by adding capabilities such as batch management and control, information management,
or asset management, while maintaining the capability to meet critical process control, availability,
and safety requirements.
Field device integration and
asset management
In addition to supporting the most extensive range of I/O products in the industry, the core system
provides integration with:
field devices such as HART, FOUNDATION Fieldbus, and PROFIBUS PA devices for process
instrumentation.
DeviceNet, ControlNet, and EtherNet/IP industrial control devices.
These interfaces provide in-depth integration when used with our device integration tools developed
through our partnership with Endress+Hauser for process instrumentation and drives and motor
controls from Rockwell Automation. Asset management capabilities include code management,
vibration monitoring, and device management.
Batch management and control The PlantPAx system enables flexible production, equipment-independent recipe management,
batch-independent equipment control, and support for regulatory compliance. These solutions are
scalable and leverage industry standards to meet small, basic batch and sequencing needs, as well
as distributed, comprehensive batch and sequencing needs.
Process information An integrated set of decision-making tools and dashboards provide real-time access to and analysis
of process and production information throughout the enterprise.
Produce web-based KPI dashboards and reports.
Deliver timely information to appropriate personnel throughout manufacturingderived
from various manufacturing processes.
A distributed, historical data management strategy offers localized, chassis-based, high-speed data
collection and recording, as well as site and enterprise solutions to meet the most demanding
requirements.
Critical process control and safety
systems
The PlantPAx system supports scalable solutions that meet specific requirements for availability and
safety.
ControlLogix controllers support SIL 1 and SIL 2 requirements.
GuardLogix controllers supports SIL 3 requirements.
ICS Triplex Trusted controllers support triple modular redundancy and the scalable AADvance
controllers support SIL 1, 2, and 3 capabilities in simplex, duplex, or triplex configurations. All
of the ICS Triplex solutions are CIP-enabled and part of the Rockwell Automation Integrated
Architecture.
Plantwide optimization The PlantPAx system integrates with Pavilion8 software for predictive control, environmental
performance management, and production performance management.
Infrastructure Infrastructure components are built on open industry standards, support the entire PlantPAx system,
and provide connectivity to higher level business systems.
Publication PROCES-SG001B-EN-P - September 2009 7
PlantPAx Process Automation System Overview Chapter 1
Process System Elements
A process control system can be defined with system elements (combinations
of hardware and software products).
The number of controllers in a control area depends on the controller loading.
Each controller supports a specified number of field device interfaces.
Each controller has the capacity for a specific number of control
strategies, which can be estimated based on the type of I/O connected
to a controller.
The number of servers depends on the number of:
controllers.
alarms, displays, data logs, and historian tags.
operator interfaces.
System Element Description
Process automation system server (PASS) The PASS is a required system element that provides central name resolution and look up
services. The PASS also hosts a FactoryTalk View HMI server and an RSLinx Enterprise
data server.
Operator workstation (OWS) The OWS provides an interactive graphical interface to monitor and control the process.
Engineering workstation (EWS) The EWS provides a single development platform for creating and maintaining control
strategies and for configuring system elements. The EWS is also a central storage location
for configuration management.
Application server (AppServ) Application servers provide additional system capacity, such as:
additional HMI servers for additional visualization requirements.
batch management for the system-wide batch management and control.
information systems for the collection of system process data.
asset management, code management, and field device configuration.
Controller The process controller is a multitasking, multidiscipline controller that supports
continuous, batch, discrete, and motion applications. Different control strategies are
segmented to execute at appropriate rates.
The ControlLogix controller supports continuous process applications, including Advanced
Process Control functions, with its deterministic, time-based execution mode. The
controller supports high-speed controller and motion operations by using a continuous
scan mode and supports event-driven operations using event-based control.
Maintenance workstation (MWS) The MWS, typically a laptop, provides similar functionality as the EWS and is designed to
be portable so it can be used locally to monitor and debug system problems in the field.
Independent workstation (IndWS) In an independent class architecture, the independent workstation (IndWS) combines the
rolls of the PASS, OWS, and EWS all in one computer.
Architecture Classes
Rockwell Automation leverages Integrated Architecture technologies and
products to create a scalable process architecture. The flexibility and
compatibility built into these products enable them to be applied standalone as
independent products, ideal for original equipment manufacturer (OEM)
process equipment, or integrated as a distributed automation system, ideal for
processing facilities.
Rockwell Automation characterizes a process automation system based on its
scope or architecture class. Architecture classes provide a way to define system
capabilities that can be scaled by modifying the same system elements.
Independent system architecture for unit control
Centralized system architecture for area control
Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server/
Single Client
Single Server/
Multiple Clients
Multiple Servers/
Multiple Clients
Independent Class
Architecture Example
The independent class architecture supports simpler process control
configurations. The independent class architecture supports process control
and batch functions. The independent class architecture has limited
supervisory functions because it uses only one workstation (the independent
workstation) onto which all the software is loaded. You can expand the
independent system to include site manufacturing operations, as needed.
An independent class architecture consists of these system elements:
One independent workstation. This single personal computer combines
software to provide:
PASS functionality as the process system server.
EWS functionality to configure and maintain the system.
OWS functionality for the interactive graphical interface by using
custom graphics, faceplates, alarms, data logging, and trends.
Typically five process controllers with 125 complex regulatory-control
strategies (loops) per controller, with a system maximum of 375 control
strategies.
64 I/O modules on an unscheduled, remote I/O ControlNet network.
I/O components that are any I/O type and nominally 1024 points per
controller (2048 points if hybrid system with higher discrete control),
with this distribution:
250 analog inputs (4...20 mA or HART devices).
125 analog outputs (4...20 mA or HART devices).
400 digital inputs.
200 digital outputs.
4 specialty modules (such as FOUNDATION Fieldbus linking
devices, PROFIBUS PA bridges, or DeviceNet bridges).
Networked motor control center devices can be used in place of
standard I/O modules (digital and analog outputs). A networked MCC
supports as many as 45 devices, typically:
10 variable frequency drives (count as analog devices).
35 motor starters (count as digital devices).
Optional MWS as a laptop.
This diagram shows an example independent class architecture.
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Centralized Class
Add workstations to expand the independent class architecture to a centralized
class architecture that supports:
multiple OWS through out the production area, a centralized EWS for
system-wide development, and optional application servers for
functions, such as batch and asset management.
additional controllers in the system.
optional reporting, information management, data collection, and
process optimization.
The centralized system is a multi-client configuration that supports the
concept of automating a single production or process area. The system
elements can provide main control room operation and enable you to mount
operator workstations locally throughout the production facility. The
centralized system expands the independent system by adding:
one dedicated PASS as the central HMI server.
one dedicated EWS for the development and maintenance of the full
system, including system security.
multiple OWS for the interactive graphical interface.
application servers for batch management, data acquisition (historian),
or change management (asset management).
multiple MWS, typically laptops, for system maintenance.
A centralized system supports these system elements:
One PASS.
As many as eight OWS.
Typically five process controllers with 125 complex regulatory-control
strategies (loops) per controller, with a system maximum of 500 control
strategies.
64 I/O modules nominally on an unscheduled, remote I/O ControlNet
network.
400 digital inputs.
Multiple MWS as laptops.
This diagram shows an example centralized class architecture.
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9

Distributed Class
The distributed class architecture expands on the centralized class by adding
application servers to interconnect multiple process areas into a system. The
flexibility of the distributed system lets you implement large, distributed
systems across a plant, mill, or manufacturing facility and consistently integrate
all control facets under a single architecture.
The distributed system is a multi-server, multi-client configuration that
supports automating a process with semi-independent areas. The distributed
system supports:
dedicated PASS.
dedicated EWS for the development and maintenance of the full system,
including system security.
multiple OWS for the interactive graphical interface.
multiple application servers for batch management, information
management, or change management (asset management).
multiple, distributed HMI application servers.
multiple MWS, typically laptops, for system maintenance.
Use a distributed system for applications that require independent, but
connected, control areas. Typical distributed systems include independently
operated production lines. A distributed system can have up to four control
areas. Each of the four control areas supports these elements:
One PASS.
As many as eight OWS.
One central EWS.
Typically 5 process controllers with 125 complex regulatory-control
strategies (loops) per controller, with a system maximum of 2000
control strategies.
64 I/O modules nominally on a unscheduled, remote I/O ControlNet
network.
400 digital inputs.
Multiple MWS as laptops.
This diagram shows an example distributed class architecture.
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Recommended
Architecture Sizes
Use these system elements in your process architecture.
System Element Independent Class Centralized Class Distributed Class
Independent
workstation
Independent workstation (single
computer) functions as:
PASS
EWS
OWS
None None
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
PASS Included in independent
workstation
HMI supports these on scan:
1000 active display points
1000 alarms with Acks per
controller
50 data log points logged
per second per controller
One PASS required and includes:
FactoryTalk Directory server
HMI server
Data server
PASS supports:
1000 display points per
OWS
controller
One PASS required and includes:
FactoryTalk Directory server
HMI server
Data server
PASS supports:
OWS
controller
Application servers None One batch server One batch server for each set of six
controllers
Three AppSer-HMI, each with:
OWS
controller
OWS Included in independent
workstation
8 remote clients 8 remote clients for PASS
8 additional remote clients per
AppSer-HMI
Domain controller Required if there are 10 or more
Ethernet nodes (IP addresses)
Required Required
Process controller 1...5 ControlLogix controllers
125 control strategies
(loops) per controller at a
250 ms period
375 total control strategies
per system
1...6 ControlLogix controllers
250 ms period
per system
1...6 ControlLogix controllers per
PASS
1...6 ControlLogix controllers per
AppSer-HMI
250 ms period
per system
Chapter 2
PlantPAx Core System
Introduction
The PlantPAx core system consists of the components required to engineer
and maintain a process system. This includes system servers, workstations, and
controllers. The core system also includes interfaces to field devices, including
I/O modules, linking devices and bridges, as well as the network
infrastructure.
COMM STATUS
In
In
Channel A
Channel B
REDUNDANT COAX BARRIER
Operator Workstation
(OWS)
Process Automation
System Server
(PASS)
Domain
Controller
Engineering
Workstation
(EWS)
System
Printers
ControlNet
Network
Redundant
Controllers
Local Operator
Workstation
EtherNet/IP
Network
Remote I/O Racks
FOUNDATION
Fieldbus
Network
Intrinsically Safe Area
HART I/O
XM Condition
Monitoring
CENTERLINE
Motor Control Center
FOUNDATION
Fieldbus
Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
Chapter 2 PlantPAx Core System
Core Control Hardware
The core control components are the ControlLogix family of products. The
ControlLogix controller functions as the process controller and provides
process, sequential, discrete, and drive control. Separate modules provide
connectivity to system networks, field devices, and third-party products.
Additional Resources
Control Hardware
Hardware Product
Process controller ControlLogix 1756-L63 controllers
Firmware revision 17.0, nonredundant controller
Firmware revision 16.8, redundant controller
I/O modules 1756 discrete, analog, and specialty
Redundancy modules
1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)
(1)
1757-SRM
Ethernet interface (supervisory network) 1756-EN2T, 1756-EN2F
1756-ENBT
1756-EWEB
ControlNet interface (peer-to-peer network) 1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
I/O interface (downlink) 1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
Display devices 1700 integrated display computer
(1)
PhaseManager and FactoryTalk Alarms and Events applications require this enhanced redundancy solution.
Resource Description
ControlLogix Selection Guide, publication 1756-SG001 ControlLogix system components.
NetLinx Selection Guide, publication NETS-SG001 EtherNet/IP, ControlNet, and DeviceNet network components.
Visualization Platforms Selection Guide, publication VIEW-SG001 Operator interface terminals, industrial computers and monitors,
HMI software, and message display components.
PlantPAx Core System Chapter 2
Core Servers and
Workstations
The PlantPAx system uses these core servers and workstations:
Process automation system server (PASS)
Engineering workstation (EWS)
Operator workstation (OWS)
Process Automation System Server (PASS)
The process automation system server (PASS) is the process system server.
The PASS can also provide HMI, data, and OPC server functions.
Computer Requirements - PASS
Attribute Requirement
Computer hardware Pentium 4 processor or better
3.0 GHz CPU
2 GB memory
Dual hard drives (one for application code; one for logging)
Dedicated Ethernet card that supports redundant media
UPS power backup
Software - PASS
Software Product
Operating system Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW
service)
Visualization software FactoryTalk View SE server software
FactoryTalk View SE client software
FactoryTalk View Studio software
(1)
Infrastructure software FactoryTalk Services Platform server software
FactoryTalk View Administration Console software
RSLinx Enterprise software (includes FactoryTalk Alarms and Events server)
RSLinx Classic software (not activated)
Logix5000 Clock Tool software
FactoryTalk Activation server software
FactoryTalk Historian interface node
Optional software Microsoft Office 200x software
Antivirus software
Diskeeper software
OPC interface software
(1)
Required only for initial setup. Take advantage of concurrent licensing with an EWS.
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.
Computer Requirements - EWS
3.0 GHz CPU
3 GB memory
ATI video card
Dedicated Ethernet card
UPS power backup
Software - EWS
Software Product
Operating system Windows XP Professional operating system
Windows 2003 Server operating system (if more than 10 nodes and activation server)
Control development software RSLogix 5000 Professional Edition software (includes Advanced Process Control
function blocks)
RSLogix Architect software
RSLogix Emulate 5000 software
Visualization development software FactoryTalk View SE client software
FactoryTalk View Studio software
Batch development software (optional)
(1)
FactoryTalk Batch Equipment Editor software
FactoryTalk Batch Recipe Editor software
FactoryTalk Batch View client software
Material management software (optional)
(1)
FactoryTalk Batch MaterialManager software
Asset management development software
(optional)
(1)
FactoryTalk AssetCentre client software
FactoryTalk AssetCentre audit support
Process information software (optional)
(1)
FactoryTalk Historian Process Book software
FactoryTalk Historian Datalink software
FactoryTalk Historian Batch View software
FactoryTalk Historian SQC software
FactoryTalk VantagePoint development tools
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 application
HMI server. The OWS supports operator interaction and is not meant to
support development or maintenance activities.
Infrastructure software FactoryTalk Services Platform software
RSLinx Enterprise software
RSLinx Classic software
(2)
FactoryTalk Security server software
(1)
Optional configuration software Fuzzy Designer software
IntelliCENTER software for motor control centers
RSFieldbus software for FOUNDATION Fieldbus devices
HIPROM HSNetworxPA software for PROFIBUS PA devices
Endress+Hauser Fieldcare software
Antivirus software
Diskeeper software
(1)
The EWS has the client and configuration tools. You need the associated application server for runtime services.
(2)
Included with RSLogix 5000 Professional Edition software.
Software - EWS
Software Product
Computer Requirements - OWS
2.0 GHz CPU
1 GB memory
ATI video card
UPS power backup
Independent Workstation
The independent workstation (IndWS) is a single computer that contains all
the system software to develop, operate, and maintain an independent process
application. The IndWS integrates the functions of multiple servers (PASS and
other application servers) and workstations (EWS and OWS) into one
computer.
Software - OWS
Software Product
Operating system Windows XP Professional operating system
Visualization software FactoryTalk View SE client software
Batch software (optional)
(1)
FactoryTalk Batch client software
FactoryTalk Batch eProcedure software
Process information software (optional)
(1)
FactoryTalk Historian Active View (ProcessBook) client software
Infrastructure software FactoryTalk Services Platform software
FactoryTalk Activation client software
Antivirus software
Diskeeper software
(1)
The OWS has the client and configuration tools. You need the associated application server for runtime services.
Computer Requirements - IndWS
3.0 GHz CPU
2 GB memory
ATI video card
UPS power backup recommended
Predefined Servers and Workstations
These servers and workstation are available as prepackaged hardware and
software products based on the PlantPAx characterized system elements.
Engineering Tools
The PlantPAx solution includes additional tools that can be used to develop
your process application, in conjunction with the standard Integrated
Architecture tools such as RSLogix 5000 software.
Access engineering tools and associated documents from:
http://rockwellautomation.custhelp.com/cgi-bin/rockwellautomation.cfg/ph
p/enduser/std_adp.php?p_faqid=62366.
Some downloads may require a TechConnect contract.
Cat. No. Description
7477-IS2VS100 Process automation system server (PASS) with 100 screens
7477-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support
process devices (such as valve, motor, and transmitter) consisting of:
controller logic (Add-On Instructions).
graphical objects for custom graphics and custom faceplates.
Field instrument library Device integration tools provide access to isolated diagnostics and step-by-step guidance
on connectivity, configuration, and commissioning of field devices with the PlantPAx
system. These tools include:
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.
Application development The Logix View utility is an engineering tool that helps you bulk generate portions of your
application based on libraries of logic and human interface components.
Create logic templates from your control logic libraries and define how to map tags
when creating instances.
Create display templates from your visualization libraries and define how to map tags
when creating instances.
Contact your local office for this utility.
Notes:
Chapter 3
PlantPAx Field Device Integration and
Asset Management
Introduction
Field device components include interfaces, instruments, actuators, drives, and
field devices. These components include DeviceNet, HART, FOUNDATION
Fieldbus, and PROFIBUS PA devices.
COMM STATUS
In
In
Channel A
Channel B
Asset
Management
ControlNet
Network
Redundant
Controllers
EtherNet/IP Network
HART I/O
XM Condition
Monitoring
CENTERLINE
Motor Control
Center
FOUNDATION
Fieldbus
Network
EtherNet/IP Network
PROFIBUS PA
Network
PowerFlex
Drives
Topic Page
EtherNet/IP Devices 26
ControlNet Devices 27
DeviceNet Devices 28
HART Devices 30
FOUNDATION Fieldbus Devices 31
PROFIBUS PA Devices 33
Asset Management 35
Chapter 3 PlantPAx Field Device Integration and Asset Management
EtherNet/IP Devices
The Industrial Ethernet (EtherNet/IP) network protocol is an open
industrial-networking standard that supports both real-time I/O messaging
and message exchange. The EtherNet/IP network uses off-the-shelf Ethernet
products and physical media.
In a PlantPAx system, the Ethernet IP provides the communication backbone
for the supervisory network for the workstations, servers, and the controllers.
The EtherNet/IP network can also function as a controller down link (remote
IO network), but not with redundant controllers.
EtherNet/IP Products
Category Product Description
ControlLogix controller interface 1756-EN2T, 1756-EN2F
1756-ENBT
1756-EWEB
Operates as ControlLogix EtherNet/IP scanner.
In-cabinet I/O modules 1734 POINT I/O 1734-AENT adapter.
1794 FLEX I/O 1794-AENT adapter.
1797 FLEX Ex intrinsically safe I/O 1794-AENT adapter (use with 1797-BIC isolator and 1797-CEC
connector to connect to hazardous areas).
On-machine I/O modules 1732 ArmorBlock I/O Built-in adapter in base block.
1738 ArmorPoint I/O 1738-AENT adapter.
Chassis-based I/O modules 1756 ControlLogix I/O 1756-EN2T, 1756-EN2F, or 1756-ENBT module.
Soft motor starter 150 SMC Flex Built-in adapter.
Variable frequency drive PowerFlex Use one of these options:
20-COMM-E adapter
Embedded Ethernet port on PowerFlex 755 drive.
POINT I/O Selection Guide, publication 1734-SG001 1734 POINT I/O modules.
FLEX I/O and FLEX Ex I/O Selection Guide, publication 1794-SG002 1794 FLEX and 1797 FLEX Ex I/O modules.
ArmorBlock MaXum I/O and ArmorBlock I/O Selection Guide,
publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock I/O modules.
ArmorPoint I/O Selection Guide, publication 1738-SG001 1738 ArmorPoint I/O modules.
PowerFlex Logw Voltage Drives Selection Guide, publication
PFLEX-SG002
PowerFlex drives.
http://www.rockwellautomation.com/encompass Encompass Program product directories.
PlantPAx Field Device Integration and Asset Management Chapter 3
ControlNet Devices
The ControlNet network is an open, control network for real-time,
high-throughput applications. The ControlNet network uses the Common
Industrial Protocol (CIP) to combine the functionality of an I/O network and
a peer-to-peer network, providing high-speed performance for both functions.
The ControlNet network gives you deterministic, repeatable transfers of all
mission-critical control data in addition to supporting transfers of
non-time-critical data. I/O updates and controller-to-controller interlocking
always take precedence over program uploads and downloads and messaging.
In a PlantPAx system, the ControlNet network is recommended for controller
downlinks and connections to remote I/O and field device interfaces. The
ControlNet network supports both standard and redundant architectures.
ControlNet Products
ControlLogix controller interface 1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
Operates as ControlLogix ControlNet scanner.
In-cabinet I/O modules 1734 POINT I/O 1734-ACNR adapter (redundant).
1794 FLEX I/O Use one of these adapters:
1794-ACN15 adapter.
1794-ACNR15 adapter (redundant).
1794-ACN15K adapter, conformal coated.
1794-ACNR15K adapter (redundant), conformal coated.
1797 FLEX Ex intrinsically safe I/O Use one of these adapters:
1797-ACNR15 adapter (redundant).
1794-ACN15 adapter (use with 1797-BIC isolator and
1797-CEC connector to connect to hazardous areas).
1794-ACNR15 adapter (redundant; use with 1797-BIC
isolator and 1797-CEC connector to connect to hazardous
area).
On-machine I/O modules 1738 ArmorPoint I/O 1738-ACNR adapter with TNC connector (redundant).
Chassis-based I/O modules 1756 ControlLogix I/O Use one of these adapters:
1756-CN2 adapter.
1756-CN2R adapter (redundant).
1756-CNB adapter.
1756-CNBR adapter (redundant).
Variable frequency drive owerFlex Use one of these adapters:
20-COMM-C coax adapter.
20-COMM-Q fiber adapter.
DeviceNet Devices
The DeviceNet network is an open low-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.
In a PlantPAx system, the DeviceNet network connects networked control
devices.
ArmorPoint I/O Selection Guide, publication 1738-SG001 1738 ArmorPoint I/O modules.
PFLEX-SG002
PowerFlex drives.
DeviceNet Products
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner.
In-cabinet I/O modules 1734 POINT I/O Use one of these adapters:
1734D POINTBlock series, interface with integrated I/O.
1734-ADN adapter.
1734-ADNX adapter with subnet connectivity.
1734-PDN communication interface.
1790 CompactBlock LDX I/O Built-in adapter in base block.
1791D CompactBlock I/O Built-in adapter in base block; DeviceLogix Smart Component
Technology.
1794 FLEX I/O 1794-ADN adapter.
1797 FLEX Ex intrinsically safe I/O 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC
connector to connect to hazardous areas).
On-machine I/O modules 1732 ArmorBlock I/O Built-in adapter in base block.
1738 ArmorPoint I/O Use one of these adapters:
1738-ADN12 adapter with M12 quick-disconnect
terminations.
1738-ADN18 adapter with mini connector (drop).
1738-ADN18P adapter with mini connector (pass-thru).
1738-ADNX adapter with subnet connectivity.
1792 ArmorBlock MaXum I/O Built-in adapter in base block; DeviceLogix Smart Component
Technology.
1799 Embedded I/O Built-in adapter; DeviceLogix Smart Component Technology.
Chassis-based I/O modules 1756 ControlLogix I/O 1756-DNB module.
1762 MicroLogix expansion I/O 1761-NET-DNI linking device.
1769 Compact I/O 1769-ADN adapter.
1771 PLC-5 I/O 1771-SDN module.
Full-voltage motor starters 193 full-voltage nonreversing
592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay.
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter.
XM condition monitoring
specialty modules
1440 Emonitor modules Built-in adapter.
DeviceNet Products
ArmorBlock MaXum I/O and ArmorBlock I/O Selection Guide,
publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock I/O modules.
ArmorPoint I/O Selection Guide, publication 1738-SG001 1738 ArmorPoint I/O module.
Embedded I/O For DeviceNet Technical Data, publication
1799-TD001
1799 Embedded I/O products.
PFLEX-SG002
PowerFlex drives.
HART Devices
Highway Addressable Remote Transmitter (HART) is an open protocol
designed to connect analog devices. For HART connectivity, select from
products available from Rockwell Automation and our Encompass partners.
PlantPAx systems interface directly with HART instruments through
HART-capable distributed IO modules.
HART technology provides digital data (diagnostic information) in addition to
analog. Device integration tools provide access to isolated diagnostics and
step-by-step guidance on connectivity, configuration, and commissioning of
Endress+Hauser HART field devices with the PlantPAx system. These tools
include:
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.
HART Products
Chassis-based I/O modules 1756-IF8H
1756-OF8H
ControlLogix analog I/O modules with:
standard profiles in RSLogix 5000 software.
DTMs.
MVI56-HART Prosoft ControlLogix I/O module.
Distributed 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:
standard profiles in RSLogix 5000 software.
DTMs.
1769-sc-IF4IH
1769-sc-OF4IH
Spectrum Compact I/O modules.
Multiplexers/gateways FPIO-I8H-EIP FieldPort device
FPIO-O8H-EIP FieldPort device
Spectrum gateways.
2700 HART Multiplexer Pepperl+Fuchs HART multiplexer; requires a multiplexer
termination panel, such as HPSM/32/MM-01.
5100 serial gateways
6000 wireless gateways
ProSoft gateways.
Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product.
FOUNDATION Fieldbus
Devices
The FOUNDATION Fieldbus network is a communication network created
by the Fieldbus Foundation. It is a protocol designed for robust, distributed
control of process control applications. Devices connected by a
FOUNDATION Fieldbus network can be used for sophisticated,
highly-distributed process control.
PlantPAx systems communicate with FOUNDATION Fieldbus devices
through EtherNet/IP and ControlNet linking devices.
http://www.rockwellautomation.com/solutions/process/integration
docs.html
Integration documents.
Add-On Instructions and Faceplates for Visualizing HART Instrument
Data in FactoryTalk View SE, Knowledgebase document (Login
required. Please contact your sales representative.)
http://rockwellautomation.custhelp.com/cgi-bin/rockwellautomatio
n.cfg/php/enduser/std_adp.php?p_faqid=54857
How to implement the HART Add-On Instruction in controller logic
to work with the FactoryTalk View faceplates for HART instruments.
FOUNDATION Fieldbus Products
EtherNet/IP interface 1757FFLD2
1757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports.
ControlNet interface 1757-FFLDC2
1757-FFLDC4
Bridge from a ControlNet network to either two or four H1
ports; compatible with ControlLogix redundancy and redundant
ControlNet media.
FOUNDATION Fieldbus network
components
FD0-VC-Ex4.FF Pepperl+Fuchs discrete I/O module: four outputs; eight inputs;
intrinsically safe.
DP-LBF-I1.34 Pepperl+Fuchs surge protection modules compatible with IEC
61158-2. DIN-rail mountable base and removable module.
FN-FT-Ex1.D.IEC Pepperl+Fuchs FOUNDATION Fieldbus H1 intrinsically-safe
terminator, which screws into a 1/2 in. NPT transmitter port.
The FOUNDATION Fieldbus network offers the ability for devices to share
information with each other. Control in the field is possible on the same
segment, and the segment will continue to run even without the control
system. Field device data can also be accessed via an OPC server. Device
integration tools provide access to isolated diagnostics and step-by-step
guidance on connectivity, configuration, and commissioning of
Endress+Hauser FOUNDATION Fieldbus field devices with the PlantPAx
system. These tools include:
controller.
Power conditioning products KLD2-FBPS-1.25.360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA, 25...27V DC
isolated power supply, DIN rail.
HD2-FBPS-1.500 Pepperl+Fuchs modules for power hub motherboard providing
500 mA per FOUNDATION Fieldbus H1 segment.
HD2-FBPS-1.25.360 Pepperl+Fuchs modules for power hub motherboard providing
360 mA per FOUNDATION Fieldbus H1 segment.
MB-FB-x Pepperl+Fuchs power hub motherboard available in:
1R one redundant segment.
2R two redundant segments.
4 four segments.
4R four redundant segments.
MBHD-FB-4R Pepperl+Fuchs high-density power hub, four redundant
segments.
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring
communication signals, automated commissioning, and
troubleshooting of the fieldbus physical layer.
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on
FOUNDATION Fieldbus H1 segments and outputs a collective
fault signal.
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting
nonincendive energy to FOUNDATION Fieldbus H1. Mount
inside cabinet. Terminals for 4, 6, 8,10, and 12 spurs.
SP-JB-Nx-x.x Pepperl+Fuchs segment protector enclosures. Various housing
and connections available.
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier,
Div. 2/Zone1 mountable with Div. 1/Zone 0 outputs.
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier,
Configuration software RSFieldbus software Configure FOUNDATION Fieldbus devices.
FOUNDATION Fieldbus Products
PROFIBUS PA Devices
The PROFIBUS (Process Field Bus) PA (Process Automation) 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. The PROFIBUS PA
network is ideal for explosion-hazardous areas (Ex-zone 0 and 1).
PlantPAx systems communicate with PROFIBUS PA devices through the
EtherNet/IP-to-PROFIBUS PA linking device.
docs.html
PROFIBUS PA Products
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNet/IP to PROFIBUS PA linking
device.
PROFIBUS network components FD0-VC-Ex4.PA Pepperl+Fuchs discrete I/O module: four outputs; eight inputs;
intrinsically safe.
DP-LBF-I1.34 Pepperl+Fuchs surge protection modules compatible with IEC
61158-2. DIN-rail mountable base and removable module.
FN-FT-Ex1.D.IEC Pepperl+Fuchs PROFIBUS PA intrinsically-safe terminator, which
screws into a 1/2 in. NPT transmitter port.
PROFIBUS PA device integration uses the 1788HP-EN2PA module as an
Ethernet PA master, linking directly to the PA bus and connecting PA field
devices to the ControlLogix controller. Device integration tools provide access
to isolated diagnostics and step-by-step guidance on connectivity,
configuration, and commissioning of Endress+Hauser PA field devices with
the PlantPAx system. These tools include:
controller.
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring
communication signals, automated commissioning, and
troubleshooting of the fieldbus physical layer.
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on
PROFIBUS PA segments and outputs a collective fault signal.
HD2-FBPS-1.500 Pepperl+Fuchs modules for power hub motherboard providing
500 mA per PROFIBUS PA segment.
HD2-FBPS-1.25.360 Pepperl+Fuchs modules for power hub motherboard providing
360 mA per PROFIBUS PA segment.
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DP/PA gateway, four PA segments.
MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway.
MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway.
MB-FB-4.GEN Pepperl+Fuchs power supply motherboard, four segments.
MB-FB-4R.GEN Pepperl+Fuchs power supply motherboard, four redundant
segments.
KT-MB-GTR-2PA Compact segment coupler kit - two PA segments -DP/PA
segment coupler and power modules and motherboard.
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting
nonincendive energy to the PROFIBUS PA network. Mount
inside cabinet. Terminals for 4, 6, 8,10, and 12 spurs.
SP-JB-Nx-x.x Pepperl+Fuchs segment protector enclosures. Various housing
and connections available.
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier,
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier,
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices.
PROFIBUS PA Products
Asset Management
Asset management is an extension to the PlantPAx system that adds
maintenance and plant operations to the core components. This includes
comprehensive diagnostics, calibration, real-time monitoring, as well as
auditing equipment and network health to improve overall resource availability.
Asset Management Server
The asset management server provides a centralized system management for
end field devices.
docs.html
Computer Requirements - Asset Management Server
3.0 GHz CPU
2 GB memory
UPS power backup
Software - Asset Management Server
Software Product
Operating system Windows 2003 Server operating system
Asset management software FactoryTalk AssetCentre server software
FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software
Microsoft SQL Server 2000 software
Optional software IntelliCENTER software for motor control centers
Asset Management Products
FactoryTalk AssetCentre asset management provides a set of asset-centric
tools to help you to manage your automation and process investment.
The process device configuration tool uses Field Device Type (FDT)
technology to access instrument parameters, configure and commission
process devices, and help with diagnostics.
The calibration management tool provides a paperless calibration
solution that manages calibration requirements, specifications,
schedules, calibration results, and reports. The calibration management
tool uses the Field Calibrator Interface (FCINTF) to interface with
calibrators from a variety of vendors.
FCINTF
Asset Management Products
FactoryTalk AssetCentre Server software 9515-ASTSRVRENE FactoryTalk AssetCentre Server.
Additional assets 9515-ASTCAPxxxxE FactoryTalk AssetCentre assets
where xxxx=0005, 0025, 0100, 0500, 1000, or 5000.
Process device configuration tool 9515-ASTPRDCFENE FactoryTalk AssetCentre Process
Device Configuration.
Calibration management tool 9515-ASTCLMANENE FactoryTalk AssetCentre Calibration
Management software.
9515-ASTCLWRKENE FactoryTalk AssetCentre Calibration
Management remote workstation.
9515-ASTCLFLKENE FactoryTalk AssetCentre Calibration
Management FLUKE interface.
9515-ASTCLDRKENE FactoryTalk AssetCentre Calibration
Management Druck interface.
9515-ASTCLTMNENE FactoryTalk AssetCentre Calibration
Management Trnsmtn interface.
Calibrators Loop
705, 707, 707Ex, 715
Fluke handheld process-loop calibrators for the calibration and
troubleshooting of 4...20 mA process control loops.
Multifunction
725, 741, 743B, 744
Fluke handheld, multifunction calibrators for temperature,
pressure, voltage, and mA parameters.
Pressure
717, 718, 718Ex, 719
Fluke pressure calibrators measure pressure to 0.05%, DC mA.
The 718 and 718Ex have an onboard pump. Ranges: 30 and 100
PSIG.
Temperature
712, 714, 724
Fluke temperature calibrators include:
712: RTD source/measure.
714: thermocouple (T/C) source/measure.
724: source/measure RTD, T/C, measure mA, 24V loop.
Chapter 4
PlantPAx Batch Management and Control
Introduction
PlantPAx batch management and control solutions offer flexible production,
equipment-independent recipe management, batch-independent equipment
control, and regulatory compliance. Operation functions provide batch
visualization, analysis, and web-based reporting. These scalable integrated
solutions meet industry standards to meet small, basic batch/sequencing
needs, as well as distributed, comprehensive batch/sequencing needs.
COMM STATUS
CNet Barrier
In
In
Channel A
Channel B
Operator
Workstation
(OWS)
Process Automation
System Server
(PASS)
Domain
Controller
Engineering
Workstation
(EWS)
System
Printers
ControlNet
Network
Redundant
Controllers
Local Operator
Workstation
EtherNet/IP
Network
Remote I/O Racks
FOUNDATION
Fieldbus
Network
HART I/O
XM Condition
Monitoring
CENTERLINE
Application
Server:
Batch
Management
Application
Server:
Material
Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
Chapter 4 PlantPAx Batch Management and Control
Batch Management & Control is a critical component of many process
applications. Diverse batch processing needs range from simple, single vessel,
single product manufacturing to complex multi-path, multi-vessel,
multi-product manufacturing. Each need requires a different recipe and
management approach, such as solutions for:
fixed sequences, fixed formulation, and simple equipment control.
flexible sequences, flexible formulations, multiple unit coordination.
flexible sequences, flexible formulation, multiple unit coordination, and
networked pathway coordination.
Batch management and control also addresses other business and production
functions, such as:
process monitoring and control.
manufacturing operations.
business and supply chain integration.
information, analysis, and reporting.
regulation, standards, and best practices.
security, availability, and data integrity.
maintenance, support, and training.
The PlantPAx system supports basic batch and sequencing capabilities for
small systems through core system functions, as well as comprehensive batch
and sequencing capabilities for complex systems through modular server and
software components. The PlantPAx portfolio is scalable to meet a wide range
of batch and sequencing requirements from small to large, simple to complex.
PlantPAx Batch Management and Control Chapter 4
Basic Batch and
Sequencing
Basic batch and sequencing extends core system components to provide batch
capabilities for smaller systems.
PhaseManager software
HMI faceplates
Redundant Controller Pair
Distributed I/O Racks
FOUNDATION Fieldbus Links
ControlNet Links
The basic batch and sequencing options rely on programming to manage the
application.
Basic Batch and Sequencing Options
Option Description
Coded (custom) Coded solutions rely on core system Logix functionality (PhaseManager software and the
sequential function chart 'SFC' language) to provide basic sequencing in the controller.
This solution offers the capability for small systems to adapt standards without the
overhead of more complex batch management and control functionality. PhaseManager
software provides a repeatable, code organization model. The SFC language is the fixed
sequencing mechanism.
Generally these solutions are optimized for fixed sequences, fixed formulation, and
simple equipment control local to the process.
Configured Configured solutions extend core Logix functionality (PhaseManager software) and
FactoryTalk View functionality (standard faceplates) to provide basic batch management
and control functionality in the controller and HMI. This solution offers the capability for
small systems to adapt standards, provides local formulation management, and enables
flexible sequence definition without the overhead of more comprehensive server-based
solutions. PhaseManager software is the basis for process control code. A standard set of
HMI faceplates and the process controller provide recipe management and unit
supervision local to the controller without the need for custom code.
Generally these solutions are optimized for flexible sequences, flexible formulation, and
simple equipment control local to the process.
Coded Batch and Sequencing Products
Process controllers ControlLogix 1756-L63 controllers
Firmware revision 17.0, nonredundant
controller
Controller-based sequencing relies on the core
capabilities of the Logix controller including
PhaseManager and SFC programming.
Control logic PhaseManager software Create custom code for:
recipe management (formulas, sequences, and
equipment).
batch and sequence control.
Visualization OWS with FactoryTalk View SE software Create custom displays.
Comprehensive Batch and
Sequencing
Add comprehensive batch and sequencing capability to the core PlantPAx
system with software-based, supervisory, batch management and control for
large and complex applications. These multi-unit, multi-controller batch
management and control solutions:
give the ability develop and manage recipes through standard software.
meet the demands of validated industries.
provide for manual work instructions.
enable active material management.
connect to manufacturing and business systems.
enable collection and storage of contextual batch information.
Comprehensive batch and sequencing solutions leverage core Logix
functionality (PhaseManager software) in conjunction with batch software
(FactoryTalk Batch software). PhaseManager software continues to be the
basis for process control code in the controller. FactoryTalk Batch software
provides recipe management, information management, process management,
and unit supervision.
Configured Batch and Sequencing Products
Process controllers ControlLogix 1756-L63 controllers
Firmware revision 17.0, nonredundant
controller
Controller-based sequencing relies on the core
capabilities of the Logix controller including
PhaseManager software, Logix application, and
standard faceplates.
Control logic Logix Batch and Sequence Manager software
(Process object with PhaseManager interface)
Pre-developed Logix application add-in that
enables configurable formulas (setpoints),
procedures (sequences), and shared resources.
Available as a process object application.
Visualization Logix Batch and Sequence Manager software
(Process object with FactoryTalk View screens)
Pre-developed View application add-in that
enables configurable formulas (setpoints),
procedures (sequences), and shared resources.
Available as a process object application.
Generally these solutions are optimized for flexible sequences, flexible
formulation, multiple unit, and networked pathway coordination.
There are options depending on system size and batch server location.
Redundant Controller Pair
Distributed I/O Racks
FOUNDATION Fieldbus Links
ControlNet Links
OWS EWS Batch Server
ControlLogix Chassis with
56SAM-838 Module
Application Server:
Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a
module in the local ControlLogix chassis for smaller systems.
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online
Development, Inc. The 56SAM-838 module is an in-chassis, Windows-based server on
which you install batch server software.
Application server The application-server offers comprehensive batch management capability on a standard
application server and can be scaled to meet size and performance requirements.
The application batch server is a Windows-based server on which you install batch server
software.
You might also need a:
material management server.
information management server.
Computer Requirements - Batch Server
56SAM-838 server 1 GB memory
8 GB CompactFlash card
Application server Pentium 4 processor or better
3.0 GHz CPU
2 GB memory
Software - Batch Server
Software Product
Batch software FactoryTalk Batch server software
FactoryTalk Batch Equipment Editor software
FactoryTalk Batch Recipe Editor software
FactoryTalk Batch Client software
FactoryTalk Batch Archiver software
Infrastructure software FactoryTalk Services Platform client
FactoryTalk Activation client software
Material Management
The material management extension of batch management and control
provides an active material management and inventory system. This includes
material-based phase definitions in batch execution that enables just-in-time
material and equipment selection to provide flexible batch manufacturing and
real-time production scheduling.
Material Management Server
The material manager server integrates with company-wide inventory
management systems. The server complements ERP-level resource
management by collecting the detailed material and equipment tracking
information.
Application Servers (redundant) -
Batch Management
Application Servers (redundant) -
Material Management
Controller and Field
Device Interfaces
EtherNet/IP Network
Link to Distributed I/O
Software - Material Management Server
3.0 GHz CPU
2 GB memory
Software - Material Management Server
Software Product
Material management software FactoryTalk Batch MaterialManager server software
Supported third-party software Symantec Antivirus software
Notes:
Chapter 5
PlantPAx Process Information
Introduction
A PlantPAx system employs a distributed, data management strategy. The
process information extension provides the tools to collect, store, and analyze
that data from a central location.
The PlantPAx process information solution offers an integrated set of
decision-making tools and dashboards that help provide real-time access to
and analysis of process and production information throughout the enterprise.
Produce web-based KPI dashboards and reports.
Deliver timely information throughout manufacturingderived from
various manufacturing processes.
COMM STATUS
CNet Barrier
In
In
Channel A
Channel B
Operator
Workstation
(OWS)
Process Automation
System Server
(PASS)
Domain
Controller
Engineering
Workstation
(EWS)
System
Printers
ControlNet
Network
Redundant
Controllers
Local Operator
Workstation
EtherNet/IP Network
Remote I/O Racks
FOUNDATION
Fieldbus
Network
HART I/O
XM Condition
Monitoring
CENTERLINE
EtherNet/IP Network
Application
Server:
Batch
Management
Application
Server:
Material
Management
Application Server:
Information Management
Chapter 5 PlantPAx Process Information
Information Management
An information management server manages the decision-making tools and
dashboards that provide real-time and historical access to and analysis of
process information. The information management server manages both:
data management.
decision support.
Information Management Server Products
Historical data FactoryTalk Historian software
FactoryTalk Alarms and Events software
FactoryTalk Batch software
These application manage:
distributed data collection to collect and verify contextual
process data.
storage management to reliably and efficiently store data with
easy access.
Decision support FactoryTalk VantagePoint software The decision support functions provide:
comprehensive view of plant operations.
presentation, analysis, and reporting resources.
Computer Requirements - Historical Data Server
3.0 GHz CPU
2 GB memory
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW
service)
Data management software FactoryTalk Historian server software
Decision support software FactoryTalk VantagePoint software
Infrastructure software FactoryTalk Services Platform server software
Microsoft reporting services
Antivirus software
Diskeeper software
MSSQL Server software
SQL Server 2005 software (can be remote)
FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software
Concurrent or Named User client licenses
Data source connectors for databases and enterprise applications
Chapter 5 PlantPAx Process Information
Notes:
Chapter 6
PlantPAx Plantwide Optimization
Introduction
Complex industrial processes make it challenging to be both market-driven
and run profitable operations. Manufacturers reformulate their production
methodology - introducing a greater variety of higher value products, more
frequent changeovers, and shorter production runs. Manufacturers find new
ways to increase their agility in order to quickly respond to changing demand
and profitably capitalize on new market opportunities.
The Pavilion8 software platform from Pavilion Technologies, a Rockwell
Automation company, is a modular software platform that includes modules to
control, analyze, monitor, visualize, warehouse, and integrate. Model Predictive
Control (MPC) technology is an intelligence layer on top of basic automation
systems that continuously drives the plant to achieve multiple business
objectivescost reductions, decreased emissions, consistent quality, and
production increasesevery production minute. 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.
6 10 13
25
33
39
50
64 70
92
115
66 1100 13
25 25
33 33
39 39
50 50
64 64 70
92 92
115
Soft
Sensors
Controller
Metrics
Console
SCADA/HMI
Services
Control
Systems
MES
Systems
Custom
Database
Plant
Historians
SPC/SQC
Systems
Laboratory
Systems
Maintenance
Systems
Dynamic MPC
Chapter 6 PlantPAx Plantwide Optimization
Pavilion Platform
Use the Pavilion platform within a PlantPAx system to add model predictive
control, environmental performance management, and production
performance management.
Computer Requirements - Pavilion Platform
Client hardware Pentium III processor
500 MHz CPU
0.25 GB memory
0.5 GB disk space
Application server hardware Pentium 4 processor
2/4 GHz CPU
2/4 GB memory
40 GB disk space
Control application hardware Pentium III processor
500 MHz CPU
1 GB memory
40 GB disk space
Software - Pavilion Platform
Software Product
Client Windows 2003 Server operating system
Internet Explorer 6.0 software with Service Pack 1
Application sever Windows 2000, Windows XP, or Windows 2003 Server operating system
Console Service software
Pavilion Data Access Service (PDAS) software
Control application Windows 2000 or Windows XP operating system
Pavilion8 Model Predictive Control software
Chapter 7
PlantPAx Critical Process Control and Safety
Systems
Introduction
The combination of Rockwell Automation and ICS Triplex, a Rockwell
Automation company, products, the PlantPAx system supports expanded
process safety offerings that provide high levels of availability and of safety and
critical process control.
SIL 2 Controller for Fail Safe
or Fault Tolerance
Safety System
Development Workstation
(IsaGraph)
Scalable Controller for SIL 2
and SIL Fail Safe and Fault
Tolerance
TMR SIL 3 Safety
Controller and I/O
1400 Termination Board
Topic Page
High Availability Systems 54
ControlLogix SIL 1 and SIL 2 Systems 55
ICS Triplex SIL 2 and SIL 3 Systems 58
Chapter 7 PlantPAx Critical Process Control and Safety Systems
High Availability Systems
Critical processes requires systems with high availability to:
maintain production.
protect against equipment or product losses.
protect against unplanned interruptions or potential hazards.
Availability is the probability that a system is operating successfully when
needed. Availability (A) is calculated by using this formula:
A = MTBF / (MTBF + MDT)
where:
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity, including reliability and
maintainability. Reliability is the likelihood that a device will perform its
intended function during a specific period of time. Maintainability is the ability
of a system to be changed or repaired.
Redundant ControlLogix
Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
PlantPAx Critical Process Control and Safety Systems Chapter 7
ControlLogix SIL 1 and SIL 2
Systems
Safe, reliable systems safeguard people, property, the environment, and
reputations. Safety Integrity Level 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.
The following examples show ControlLogix configurations that meet SIL 1
and SIL 2 certifications for fail safe and fault tolerant requirements.
High Availability Products
Product Description
Process controller Redundant ControlLogix 1756-L63 controllers:
Firmware revisions 16.56 and 16.80
Redundant Add-On Instructions
I/O modules 1756 discrete, analog, specialty, and HART modules
1794 FLEX I/O discrete, analog, specialty, and HART modules
Redundancy modules 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)
1757-SRM
Ethernet interface (supervisory network) 1756-EN2T, 1756-EN2F
1756-ENBT
ControlNet interface (peer-to-peer network) 1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
I/O interface (downlink) 1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)
Redundant FactoryTalk View SE with automatic switchover
FactoryTalk Live Data services
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications, a programming
terminal is not normally connected.
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or
EtherNet/IP Network
Connect to other
safety-related
ControlLogix and other
remote I/O chassis.
SIL-2 certified
ControlLogix
components are within
the overall safety loop.
Remote I/O Chassis A
Remote I/O Chassis B
ControlNet or
EtherNet/IP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the
ControlLogix portion of the SIL-2 certified loop.
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser
instruments includes integration documents, Add-On Instructions, and
faceplates.
For SIL applications, a programming
terminal is not normally connected.
SIL-2 certified
ControlLogix
components are within
the overall safety loop. Sensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or
EtherNet/IP Network
Connect to other safety-related
ControlLogix and other remote
I/O chassis.
ControlNet or
EtherNet/IP Network
Connect to non-safety related systems outside the
ControlLogix portion of the SIL-2 certified loop.
This workstation is for diagnostics and visualization
(read-only access to controllers in the safety loop).
SIL Rated Instruments
Product Description
SIL 2 Endress+Hauser instruments Promass 83 Coriolis mass flow
Prowirl 73 Vortex flow
Levelflex M FMP40 guided radar level
Micropilot M FMR240 radar level
iTEMP TMT182 temperature transmitter
SIL 3 Endress+Hauser instruments Cerabar S PMC71 pressure
Deltabar S PMD75 differential pressure
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.
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.endress.com/eh/productDBs/homeDBs/en/home.nsf/c
ontentview/13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser.
AADvance Safety
Control System
IsaGraph Development
Workstation
Trusted TMR
Control System
ICS Triplex technology is available only as a complete system from ICS
Triplex, a Rockwell Automation company. For information, see
http://www.icstriplex.com
ICS Triplex Products
Product 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:
configurable for SIL 2 and SIL 3.
scalable redundancy for fault tolerance.
simplex, duplex, or triplex configuration.
Notes:
Chapter 8
PlantPAx Infrastructure
Introduction
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. In addition, the PlantPAx system
leverages best-of-breed technology partners where it makes sensedelivering
maximum value without relying on proprietary hardware and software.
Domain Controller
A domain controller manages access to network resources (such as
applications and printers) for a group of users. Each user need only to log in to
the domain to gain access to the resources, which may be located on a number
of different servers in the network.
Topic Page
Domain Controller 61
Ethernet Hardware 62
System Software and Services 63
Computer Requirements - Domain Controller
Hardware Pentium processor
2.0 GHz CPU
1 GB memory
Software Windows 2003 server
No application software
Configuration Hyper-threading optional
DHCP enabled with IP address reservation
Active directory
Kerberos authentication protocol
DNS server
WINS server
No routing
No firewall
No power management
No screen saver
Chapter 8 PlantPAx Infrastructure
Follow these guidelines for the domain controller:
A domain controller is required if there are 10 or more Ethernet nodes
(IP addresses).
The domain controller is a separate computer. Do not load any
application software on the 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 the
domain controllers, and certainly not applications that require more
than Authenticated User privileges to run.
The domain controller must be local to the system workstations and
servers (within the local firewall) and not remote to the system.
Ethernet Hardware
Infrastructure components that integrate enterprise, manufacturing, and plant
floor environments include Ethernet switches.
Hardware Product
Stratix switches In the core system, to effectively manage real-time control and information flow, Stratix
Ethernet switches integrate Cisco technology to support flexible topologies.
Stratix 8300 layer 3 (supervisory), modular managed switches
Stratix 8000 layer 2 (supervisory), modular managed switches
Stratix 6000 fixed managed switches
Stratix 2000 unmanaged switches
Cisco switches Supervisory switches at higher levels of the process system include:
Layer 2, managed switch, such as Cisco Catalyst 2950 series or equivalent Rockwell
Automation approved switch (Encompass partner)
Layer 3, managed switch, such as Cisco Catalyst 3760 series or equivalent Rockwell
Automation approved switch (Encompass partner)
PlantPAx Infrastructure Chapter 8
System Software and
Services
System software and services are used across all of the system components.
Software Description
FactoryTalk Security software Provides a wide range of security services that are integrated into the FactoryTalk
Directory services. FactoryTalk Security services provide centralized authentication and
access control.
One place to create, grant rights, and monitor all users of the system
Simplification of regulatory compliance
A robust security solution
FactoryTalk Activation software Provides a secure, software-based system for activating Rockwell Automation software
products and managing software activation files. These services install with each
participating product.
No activation media to manage
Simple method for obtaining a floating or borrowed license
Enables electronic software distribution
FactoryTalk Alarms and Events software Set of integrated services and software components that let multiple FactoryTalk products
participate in a common, consistent view and management of alarms and events
throughout a system.
Consistent user interface for visualization and management across the entire system
Virtually no HMI alarm configuration required
Significant reduction in network traffic due to alarm reporting by exception
FactoryTalk Directory software Lets products share a common address book that finds and provides access to plant-floor
resources, such as users, roles, tags, and graphic displays.
Define it once, use it everywhere and do not duplicate
Logical naming eases redeployment of physical servers
Chapter 8 PlantPAx Infrastructure
Notes:
Chapter 9
PlantPAx Migration Tools
Introduction
Rockwell Automation provides a DCS migration program to assist customers
and integrators with migrating legacy DCS systems to PlantPAx systems.
Rockwell Automation works internally and with partners to develop tools and
to support migration and conversion projects. This program also works to
develop engineering competence and capacity within Rockwell Automation
and its partners for planning, executing, and supporting DCS migration
projects.
Rockwell Automation supports the migration of these systems to PlantPAx
systems:
ABB (Bailey) Net90 and Infi90 control systems.
Honeywell TDC 2000, TDC 3000, and TPS systems.
Honeywell IPC620 programmable logic controllers.
Emerson (Fisher Controls) PROVOX systems.
Invensys (Foxboro) I/A systems.
Rockwell Automation ProcessLogix (PLx) systems.
For each system, there is a general migration plan that describes the particular
goals and methods for system migration, as well as specifics on the tools
currently available for migrating that system.
Other systems for which Rockwell Automation has tools and services include:
Emerson (Westinghouse) WDPF and WDPF II systems.
NovaTech D/3 systems (original company (EMC Electronic Modules
Corp) and its technology (S/3 and D/3) went through multiple
acquisitions, including Rexnord, Banner, Texas Instruments, and GSE) .
Siemens (Moore) APACS systems.
Schneider (Square D originally, Crisp Automation) CRISP systems.
Rockwell Automation provides extensive migration and integration capabilities
for PLC-based systems and other third-party systems.
Chapter 9 PlantPAx Migration Tools
Migration Tools
Migration tools take the following forms:
Products that become a part of the system during a migration, or may
become a permanent part of the target solution, such as I/O cables,
I/O scanners, and application codes.
Utilities that assist with converting engineering information from the
original control system to a PlantPAx system, such as database
conversion utilities.
Services that provide engineering and logistical support to migration
projects to assist with converting engineering configuration and
applications to the PlantPAx environment, such as manual database
conversions and operator graphics conversions.
The following table presents a description of tools available for legacy DCS
migration support. Not all tools are available for each target legacy DCS
system.
Available Migration Tools
System Function Tool
ABB
Bailey Net90 and Infi90
Communication RoviSys OPC90 server
Online Development RA56-cATM-BLY90 Bailey-to-Logix interface
module (1756 form factor; software preloaded)
Database conversion Rockwell Automation Bailey database conversion utility
Faceplates Rockwell Automation Bailey faceplate library
Application code Rockwell Automation Bailey control strategy library (Add-On
Instructions)
I/O interface Rockwell Automation Bailey termination cables
Honeywell
TDC2000 and TDC3000
Communication Matrikon OPC server for Honeywell APP node
Database conversion Rockwell Automation Honeywell database conversion utility
Application conversion and
simulation
Quest Honeywell MFC shadow module (ControlLogix application
shadows a MFC application)
I/O interface Rockwell Automation IPC620 I/O scanner
Rockwell Automation TDC 2000 termination cables
Rockwell Automation TDC2000/3000 termination cables
ProSoft MVI56-DEM module (1756 form factor) integrates multiple
Honeywell DE smart instruments (including ST3000 smart pressure
transmitter) to ControlLogix sysem
PlantPAx Migration Tools Chapter 9
Emerson
Fisher-Rosemount PROVOX
Communication Matrikon PROVOX direct OPC server for Data Highway access via
HDL
Online Development PROVOX Data Highway interface with
RA56-SAM module
Database conversion Rockwell Automation PROVOX database conversion utility
Faceplates Rockwell Automation PROVOX faceplate library
Application code Rockwell Automation Emerson control strategy library (Add-On
Instructions)
I/O interface Quest PROVOX S10/S20 I/O scanner
Rockwell Automation PROVOX termination cables
Invensys
Foxboro IA
Communication Matrikon Foxboro IA server
Online Development Foxboro IA Data Highway interface with
RA56-SAM module
Database conversion Rockwell Automation Foxboro IA database conversion utility
Rockwell Automation
ProcessLogix
Communication Standard connections between ProcessLogix and PlantPAx systems
Database conversion Rockwell Automation ProcessLogix database conversion utility
I/O interface I/O is already Logix-based I/O
Siemens
Moore APACS
I/O Interface Rockwell Automation APACS termination cables
Emerson
Westinghouse WDPF and WDPF
II
I/O Interface Rockwell Automation WDPF and WDPF II termination cables
Emerson
Rosemount RMV9000
I/O Interface Rockwell Automation RMV9000 termination cables
ABB
Taylor MOD300 and Advant OCS
I/O Interface Rockwell Automation I/O scanner interface for TRIO remote I/O
Available Migration Tools
System Function Tool
Chapter 9 PlantPAx Migration Tools
http://www.rockwellautomation.com/solutions/process
Or contact your local Rockwell Automation representative
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.net Prerecorded webinars on the DCS migration program and capabilities for
process customers.
Rockwell Automation Systems Solutions Business (also
known as the Manufacturing Process Solutions (MPS)
group)
Rockwell Automation partner
Rockwell Automation TechSupport
DCS migration planning and project support. Through project experience
and recent acquisitions, Rockwell Automation has extensive expertise
and experience with legacy DCS and PLC migrations.
radcsmigrations@ra.rockwell.com Email the Rockwell Automation DCS migration program.
http://www.rockwellautomation.com/solutions/process/integ
rationdocs.html
Notes:
Notes:
Notes:
Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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 TechConnect
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 an anomoly 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.
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.
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/.
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.
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.

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