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Selection Guide Coordinated Product Release 9 Logix Version 16 PlantPAx Process Automation System

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Page 1: Selection Guide

Selection Guide

Coordinated Product Release 9Logix Version 16

PlantPAx ProcessAutomation System

Important User InformationSolid 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-11 available from your local Rockwell Automation sales office or online at httpliteraturerockwellautomationcom) 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 ArmorBlock ArmorBlock MaXum ArmorPoint CENTERLINE CompactBlock ControlLogix DeviceLogix Emonitor FactoryTalk FLEX FLEX Ex GuardLogix IntelliCENTER Logix5000 MicroLogix NetLinx PhaseManager PlantPAx PLC-5 POINT RSFieldbus RSLinx RSLogix Stratix and TechConnect are trademarks of Rockwell Automation Inc

Trademarks not belonging to Rockwell Automation are property of their respective companies

WARNINGIdentifies 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

Table of Contents

Chapter 1PlantPAx Process Automation System Overview

Introduction 5Architecture Classes 7Independent Class Architecture Example 8Centralized Class Architecture Example 10Distributed Class Architecture Example 12Recommended Architecture Sizes 14

Chapter 2PlantPAx Core System Introduction 15

Core Control Hardware 16Core Servers and Workstations 17Engineering Tools 20Migration Tools and Services 21

Chapter 3PlantPAx Field Device Integration and Asset Management

Introduction 25DeviceNet Devices 26HART Devices 28Foundation Fieldbus Devices 30Profibus PA Devices 32Asset Management 35

Chapter 4PlantPAx Batch Management and Control

Introduction 37Controller-based Batch Sequencing 39Controller-based Batch Management and Control 40Chassis-based Batch Management and Control 41Application Server Batch Management and Control 43Material Management 45

Chapter 5PlantPAx Process Information Introduction 47

Process Historian 48Process Information and Decision Support 48

Chapter 6PlantPAx Plantwide Optimization Introduction 51

3Publication PROCES-SG001A-EN-P - March 2009 3

Table of Contents

Chapter 7PlantPAx Critical Process Control and Safety Systems

Introduction 53High Availability Systems 54ControlLogix SIL 1 and SIL 2 Systems 55ICS Triplex SIL2 and SIL 3 Systems 58

Chapter 8PlantPAx Infrastructure Introduction 59

Domain Controller 59Ethernet Hardware 60System Software and Services 60Rockwell Automation Support 65

4 Publication PROCES-SG001A-EN-P - March 2009

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents Rockwell Automationrsquos 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 XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

5Publication PROCES-SG001A-EN-P - March 2009 5

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

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Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 ESP 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 2: Selection Guide

Important User InformationSolid 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-11 available from your local Rockwell Automation sales office or online at httpliteraturerockwellautomationcom) 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 ArmorBlock ArmorBlock MaXum ArmorPoint CENTERLINE CompactBlock ControlLogix DeviceLogix Emonitor FactoryTalk FLEX FLEX Ex GuardLogix IntelliCENTER Logix5000 MicroLogix NetLinx PhaseManager PlantPAx PLC-5 POINT RSFieldbus RSLinx RSLogix Stratix and TechConnect are trademarks of Rockwell Automation Inc

Trademarks not belonging to Rockwell Automation are property of their respective companies

WARNINGIdentifies 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

Table of Contents

Chapter 1PlantPAx Process Automation System Overview

Introduction 5Architecture Classes 7Independent Class Architecture Example 8Centralized Class Architecture Example 10Distributed Class Architecture Example 12Recommended Architecture Sizes 14

Chapter 2PlantPAx Core System Introduction 15

Core Control Hardware 16Core Servers and Workstations 17Engineering Tools 20Migration Tools and Services 21

Chapter 3PlantPAx Field Device Integration and Asset Management

Introduction 25DeviceNet Devices 26HART Devices 28Foundation Fieldbus Devices 30Profibus PA Devices 32Asset Management 35

Chapter 4PlantPAx Batch Management and Control

Introduction 37Controller-based Batch Sequencing 39Controller-based Batch Management and Control 40Chassis-based Batch Management and Control 41Application Server Batch Management and Control 43Material Management 45

Chapter 5PlantPAx Process Information Introduction 47

Process Historian 48Process Information and Decision Support 48

Chapter 6PlantPAx Plantwide Optimization Introduction 51

3Publication PROCES-SG001A-EN-P - March 2009 3

Table of Contents

Chapter 7PlantPAx Critical Process Control and Safety Systems

Introduction 53High Availability Systems 54ControlLogix SIL 1 and SIL 2 Systems 55ICS Triplex SIL2 and SIL 3 Systems 58

Chapter 8PlantPAx Infrastructure Introduction 59

Domain Controller 59Ethernet Hardware 60System Software and Services 60Rockwell Automation Support 65

4 Publication PROCES-SG001A-EN-P - March 2009

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents Rockwell Automationrsquos 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 XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

5Publication PROCES-SG001A-EN-P - March 2009 5

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

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Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 3: Selection Guide

Table of Contents

Chapter 1PlantPAx Process Automation System Overview

Introduction 5Architecture Classes 7Independent Class Architecture Example 8Centralized Class Architecture Example 10Distributed Class Architecture Example 12Recommended Architecture Sizes 14

Chapter 2PlantPAx Core System Introduction 15

Core Control Hardware 16Core Servers and Workstations 17Engineering Tools 20Migration Tools and Services 21

Chapter 3PlantPAx Field Device Integration and Asset Management

Introduction 25DeviceNet Devices 26HART Devices 28Foundation Fieldbus Devices 30Profibus PA Devices 32Asset Management 35

Chapter 4PlantPAx Batch Management and Control

Introduction 37Controller-based Batch Sequencing 39Controller-based Batch Management and Control 40Chassis-based Batch Management and Control 41Application Server Batch Management and Control 43Material Management 45

Chapter 5PlantPAx Process Information Introduction 47

Process Historian 48Process Information and Decision Support 48

Chapter 6PlantPAx Plantwide Optimization Introduction 51

3Publication PROCES-SG001A-EN-P - March 2009 3

Table of Contents

Chapter 7PlantPAx Critical Process Control and Safety Systems

Introduction 53High Availability Systems 54ControlLogix SIL 1 and SIL 2 Systems 55ICS Triplex SIL2 and SIL 3 Systems 58

Chapter 8PlantPAx Infrastructure Introduction 59

Domain Controller 59Ethernet Hardware 60System Software and Services 60Rockwell Automation Support 65

4 Publication PROCES-SG001A-EN-P - March 2009

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents Rockwell Automationrsquos 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 XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

5Publication PROCES-SG001A-EN-P - March 2009 5

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

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PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

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Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

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Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 DAN 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 NLD ltFEFF004700650062007200750069006b002000640065007a006500200069006e007300740065006c006c0069006e00670065006e0020006f006d0020005000440046002d0064006f00630075006d0065006e00740065006e0020007400650020006d0061006b0065006e00200064006900650020006700650073006300680069006b00740020007a0069006a006e0020006f006d0020007a0061006b0065006c0069006a006b006500200064006f00630075006d0065006e00740065006e00200062006500740072006f0075007700620061006100720020007700650065007200200074006500200067006500760065006e00200065006e0020006100660020007400650020006400720075006b006b0065006e002e0020004400650020005000440046002d0064006f00630075006d0065006e00740065006e0020006b0075006e006e0065006e00200077006f007200640065006e002000670065006f00700065006e00640020006d006500740020004100630072006f00620061007400200065006e002000520065006100640065007200200035002e003000200065006e00200068006f006700650072002egt ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 4: Selection Guide

Table of Contents

Chapter 7PlantPAx Critical Process Control and Safety Systems

Introduction 53High Availability Systems 54ControlLogix SIL 1 and SIL 2 Systems 55ICS Triplex SIL2 and SIL 3 Systems 58

Chapter 8PlantPAx Infrastructure Introduction 59

Domain Controller 59Ethernet Hardware 60System Software and Services 60Rockwell Automation Support 65

4 Publication PROCES-SG001A-EN-P - March 2009

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents Rockwell Automationrsquos 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 XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

5Publication PROCES-SG001A-EN-P - March 2009 5

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 5: Selection Guide

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents Rockwell Automationrsquos 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 XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

5Publication PROCES-SG001A-EN-P - March 2009 5

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Page 6: Selection Guide

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or scale up the core up for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended through the addition of optional functions such as batch historian or asset management while providing 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 IO products in the industry the core system provides integration tobull field devices such as HART Foundation Fieldbus and Profibus PA devices for process

instrumentation

bull DeviceNet and EtherNetIP 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 controller code change management vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance Operation functions provide batch visualization analysis and web-based reporting 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 enterprisebull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturing ndash derived 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 safetybull ControlLogix controllers support SIL 1 and SIL 2 requirements

bull GuardLogix controllers supports SIL 3 requirements

bull 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 support model 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

6 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

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PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

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Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 ITA 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 7: Selection Guide

PlantPAx Process Automation System Overview Chapter 1

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

bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations

Independent

Centralized

Distributed

Single Server Single Client

Single Server Multiple Cliente

Multiple Servers Multiple Clients

Publication PROCES-SG001A-EN-P - March 2009 7

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

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Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

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  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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Page 8: Selection Guide

Chapter 1 PlantPAx Process Automation System Overview

Independent Class Architecture Example

The independent class architecture is for simpler process control configurations The independent class architecture has field devices and supports process control and batch functions The independent class architecture has limited supervisory functions in that 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 bull One independent workstation This single personal computer combines

software to function as a ndash process automation system server (PASS)ndash engineering workstation (EWS) to configure and maintain the

systemndash operator workstation (OWS) for the interactive graphical interface by

using custom graphics faceplates alarms data logging and trendsbull Maximum of five process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 375 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

8 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

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Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

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PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

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Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB ltFEFF005500740069006c0069007a006500200065007300740061007300200063006f006e00660069006700750072006100e700f5006500730020007000610072006100200063007200690061007200200064006f00630075006d0065006e0074006f0073002000500044004600200063006f006d00200075006d0061002000760069007300750061006c0069007a006100e700e3006f0020006500200069006d0070007200650073007300e3006f00200061006400650071007500610064006100730020007000610072006100200064006f00630075006d0065006e0074006f007300200063006f006d0065007200630069006100690073002e0020004f007300200064006f00630075006d0065006e0074006f0073002000500044004600200070006f00640065006d0020007300650072002000610062006500720074006f007300200063006f006d0020006f0020004100630072006f006200610074002c002000520065006100640065007200200035002e00300020006500200070006f00730074006500720069006f0072002egt DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 9: Selection Guide

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the independent class architecture

Publication PROCES-SG001A-EN-P - March 2009 9

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

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PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

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Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 10: Selection Guide

Chapter 1 PlantPAx Process Automation System Overview

Centralized Class Architecture Example

Add workstations with dedicated roles to expand the independent class architecture to a centralized class Use a centralized class architecture for applications with multiple process units that cover a large physical area and that require multiple OWS A centralized system adds capabilities such as advanced data collection (historian) complex batch control and management and basic MES interconnectivity

The centralized system is a multi-client configuration that supports the 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

bull dedicated process automation system server (PASS) as the central HMI server (optionally a redundant pair of servers)

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Maximum of six process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 500 control strategies

bull 64 IO modules per controller on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

10 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

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Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

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PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

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Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 11: Selection Guide

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the centralized class architecture

Publication PROCES-SG001A-EN-P - March 2009 11

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

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Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

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PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

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Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

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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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

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Notes

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Notes

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Notes

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Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

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  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 12: Selection Guide

Chapter 1 PlantPAx Process Automation System Overview

Distributed Class Architecture Example

The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The system elements provide main control room operation and enable you to mount OWS locally throughout the production facility The distributed system supports

bull dedicated process automation system server (PASS) as the central HMI server

bull dedicated engineering workstation (EWS) for the development and maintenance of the full system including system security

bull multiple operator workstations (OWS) for the interactive graphical interface

bull application servers for batch management data acquisition (historian) or change management (asset management)

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 these four control area supports these elements

bull One PASS (optionally a redundant pair of servers)bull As many as 32 OWSbull One central EWSbull Maximum of 24 process controllers with 125 complex regulatory

control strategies (loops) per controller with a system maximum of 2000 control strategies

bull 64 IO modules per controller on a unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller with this distributionndash 250 analog inputs (420 mA or HART devices)ndash 125 analog outputs (420 mA or HART devices)ndash 400 digital inputsndash 200 digital outputsndash 4 specialty modules (such as Foundation Fieldbus linking devices

Profibus PA bridges or DeviceNet bridges)

12 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

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Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

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PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

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Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

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Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

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PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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ltFEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e0020005000440046002d0044006f006b0075006d0065006e00740065006e002c00200075006d002000650069006e00650020007a0075007600650072006c00e40073007300690067006500200041006e007a006500690067006500200075006e00640020004100750073006700610062006500200076006f006e00200047006500730063006800e40066007400730064006f006b0075006d0065006e00740065006e0020007a0075002000650072007a00690065006c0065006e002e00200044006900650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f0062006100740020006f0064006500720020006d00690074002000640065006d002000520065006100640065007200200035002e003000200075006e00640020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002egt FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 13: Selection Guide

PlantPAx Process Automation System Overview Chapter 1

This diagram shows an example process control system based on the distributed class architecture

Publication PROCES-SG001A-EN-P - March 2009 13

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Page 14: Selection Guide

Chapter 1 PlantPAx Process Automation System Overview

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 asbull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull One EWS required

bull Can have as many as 5 EWS

bull One EWS required

bull Can have as many as 5 EWS

PASS Included in independent workstationHMI supports these on scanbull 1000 display points

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

One PASS required and includesbull FactoryTalk Directory server

bull HMI server

bull Data server

PASS supportsbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

Application servers None One batch server One batch serverThree AppSer-HMI each withbull 1000 display points per OWS

bull 1000 alarms with Acks per controller

bull 50 data log points logged per second per controller

OWS Included in independent workstation

8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI

Domain controller Optional Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 500 total control strategies per system

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMIbull 125 control strategies (complex

analog loops) per controller at a 250 ms period

bull 2000 total control strategies per system

14 Publication PROCES-SG001A-EN-P - March 2009

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

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Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

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PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

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Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

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PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 15: Selection Guide

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 IO modules linking devices and bridges as well as the network infrastructure

Section Page

Core Control Hardware 16

Core Servers and Workstations 17

Engineering Tools 20

Migration Tools and Services 21

15Publication PROCES-SG001A-EN-P - March 2009 15

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

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PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

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Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU ltFEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e0020005000440046002d0044006f006b0075006d0065006e00740065006e002c00200075006d002000650069006e00650020007a0075007600650072006c00e40073007300690067006500200041006e007a006500690067006500200075006e00640020004100750073006700610062006500200076006f006e00200047006500730063006800e40066007400730064006f006b0075006d0065006e00740065006e0020007a0075002000650072007a00690065006c0065006e002e00200044006900650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f0062006100740020006f0064006500720020006d00690074002000640065006d002000520065006100640065007200200035002e003000200075006e00640020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002egt FRA 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 PTB 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 DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 16: Selection Guide

Chapter 2 PlantPAx Core System

Core Control Hardware The core control components come from the ControlLogix family of products The ControlLogix controller is the process controller and also provides process sequential discrete and drive control Separate modules provide connectivity to system networks field devices and third-party products

Control Hardware

Additional Resources

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant controller

bull Firmware revision 165 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

bull 1756-EWEB

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Display devices bull 1700 Integrated display computer

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP 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

16 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 17: Selection Guide

PlantPAx Core System Chapter 2

Core Servers and Workstations

The PlantPAx system uses these core servers and workstationsbull Process automation system server (PASS)bull Engineering workstation (EWS)bull Operator workstation (OWS)

Computer Requirements - Workstations and Servers

Server Software - PASS

The process automation system server (PASS) is the process system server The PASS can also provide HMI data and OPC server functions

Attribute PASS and EWS OWS

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

bull Pentium 4 processor

bull 20 GHz CPU

bull 512 MB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Visualization software bull FactoryTalk View SE server software

bull FactoryTalk View SE client software

bull FactoryTalk View Studio software(1)

Infrastructure software bull FactoryTalk Services Platform server software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Live Data Interface software

bull RSLinx Enterprise software

bull RSLinx Classic software

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service (required)

Optional software bull FactoryTalk View server upgrade

bull SCADA interface software

(1) Required only for initial set up Take advantage of concurrent licensing with an EWS

Publication PROCES-SG001A-EN-P - March 2009 17

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 18: Selection Guide

Chapter 2 PlantPAx Core System

Workstation Software - 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

Software Product

Operating system bull Windows XP Professional operating system

Control development software bull RSLogix 5000 Professional Edition software

bull RSLogix Architect software(1)

bull RSLogix Emulate 5000 software(1)

bull Fuzzy Designer software (optional)

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Simulator software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

bull FactoryTalk Batch MaterialManager software

Asset management development software bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support(1)

Process information development software bull FactoryTalk Historian Process Book software (optional)

bull FactoryTalk Historian Datalink software (optional)

bull FactoryTalk Historian Batch View software (optional)

bull FactoryTalk Historian SPC software (optional)

Infrastructure software bull Windows NET Framework 20 software

bull FactoryTalk Services Platform client software

bull FactoryTalk View Administration Console software

bull FactoryTalk Historian Datalink software

bull RSLinx Enterprise software

bull RSLinx Classic software(1)

bull FactoryTalk Activation server

bull FactoryTalk security server software(1)

18 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

20 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

22 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 19: Selection Guide

PlantPAx Core System Chapter 2

Workstation Software - 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

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Configuration software (optional) bull IntelliCENTER software for motor control centers

bull RSFieldbus software for Foundation Fieldbus devices

bull HIPROM HSNetworxPA software for Profibus PA devices

bull Endress+Hauser Fieldcare software

(1) Included with RSLogix 5000 Professional Edition software

Software Product

Software Product

Operating system bull Windows XP Professional operating system

Visualization software bull FactoryTalk View SE client software

Batch software bull FactoryTalk Batch client software

Asset management software bull FactoryTalk AssetCentre client software

Process information development software bull FactoryTalk Historian Process Book Client for View software

bull FactoryTalk Historian Trend for View software

Infrastructure software bull FactoryTalk Services Platform client software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Microsoft Internet Explorer 6 software

bull Microsoft Internet IIS with WWW service

bull Microsoft Office 2007 software

Publication PROCES-SG001A-EN-P - March 2009 19

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

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PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

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Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

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PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

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PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

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Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

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Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

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Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

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Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

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PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

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Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA ltFEFF00550073006100720065002000710075006500730074006500200069006d0070006f007300740061007a0069006f006e00690020007000650072002000630072006500610072006500200064006f00630075006d0065006e007400690020005000440046002000610064006100740074006900200070006500720020006c00610020007300740061006d00700061002000650020006c0061002000760069007300750061006c0069007a007a0061007a0069006f006e006500200064006900200064006f00630075006d0065006e0074006900200061007a00690065006e00640061006c0069002e0020004900200064006f00630075006d0065006e00740069002000500044004600200070006f00730073006f006e006f0020006500730073006500720065002000610070006500720074006900200063006f006e0020004100630072006f00620061007400200065002000520065006100640065007200200035002e003000200065002000760065007200730069006f006e006900200073007500630063006500730073006900760065002egt NOR 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Page 20: Selection Guide

Chapter 2 PlantPAx Core System

Independent Workstation

The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer

Engineering Tools PlantPAx technical tools for design and development include

Attribute IndWS

Hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Category Tool

Process system library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting ofbull controller logic (Add-On Instructions)

bull graphical objects

bull templates

Application development Logix View Utility is an engineering tool which helps you bulk generate portions of your application based on libraries of logic and human interface components bull Create logic templates from your control logic libraries and define how to map tags

when creating instances

bull Create display templates from your visualization libraries and define how to map tags when creating instances

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PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

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PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

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PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

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Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

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PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA ltFEFF00550073006100720065002000710075006500730074006500200069006d0070006f007300740061007a0069006f006e00690020007000650072002000630072006500610072006500200064006f00630075006d0065006e007400690020005000440046002000610064006100740074006900200070006500720020006c00610020007300740061006d00700061002000650020006c0061002000760069007300750061006c0069007a007a0061007a0069006f006e006500200064006900200064006f00630075006d0065006e0074006900200061007a00690065006e00640061006c0069002e0020004900200064006f00630075006d0065006e00740069002000500044004600200070006f00730073006f006e006f0020006500730073006500720065002000610070006500720074006900200063006f006e0020004100630072006f00620061007400200065002000520065006100640065007200200035002e003000200065002000760065007200730069006f006e006900200073007500630063006500730073006900760065002egt NOR 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 SVE ltFEFF0041006e007600e4006e00640020006400650020006800e4007200200069006e0073007400e4006c006c006e0069006e006700610072006e00610020006e00e40072002000640075002000760069006c006c00200073006b0061007000610020005000440046002d0064006f006b0075006d0065006e007400200073006f006d00200070006100730073006100720020006600f600720020007000e5006c00690074006c006900670020007600690073006e0069006e00670020006f006300680020007500740073006b0072006900660074002000610076002000610066006600e4007200730064006f006b0075006d0065006e0074002e0020005000440046002d0064006f006b0075006d0065006e00740065006e0020006b0061006e002000f600700070006e006100730020006d006500640020004100630072006f0062006100740020006f00630068002000520065006100640065007200200035002e003000200065006c006c00650072002000730065006e006100720065002egt ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 21: Selection Guide

PlantPAx Core System Chapter 2

Migration Tools and Services

Rockwell Automation provides a DCS Migration Program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems This program provides tools for the migration of legacy (competitive) and field-proven (Rockwell Automation) systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and support projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and otherwise supporting DCS migration projects

Systems that can be migrated to PlantPAx systems includebull Bailey Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA 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 target systems include Rockwell Automation ProcessLogix Emerson (Westinghouse) WDPF Siemens (Moore) APACS and other systems

Migration Tools

Tools can reduce engineering effort and risk during system migration even though additional engineering support may be required Migration tools preserve the engineering investment in existing control systems A combination of tools and other activities extract and document existing applications of a legacy DCS system and convert them into appropriate applications within a PlantPAx system

The functional location where a particular function was performed in a legacy system may be different from the level and functional area in PlantPAx Also there may be improvements in application design and implementation which have resulted from efforts in developing engineering standards for automation and control applications

bull Legacy systems differ from PlantPAx in their general architecture and approach to control systems

bull As control systems technology has advanced increased intelligence has been driven downward in the plant information infrastructure

Publication PROCES-SG001A-EN-P - March 2009 21

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 22: Selection Guide

Chapter 2 PlantPAx Core System

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

Category Function Tools

Business systems integration bull System-to-system direct connections

bull Transactional connections

bull Direct database connections

bull Typically today these connections are replaced with a transaction brokering structure and are not replaced in kind

bull Use advanced functionality for transaction brokering

bull Update with more current database interconnectivity such as with Microsoft database interconnection tools

Production management bull Historical data collection

bull Batch management

bull There are migration tools for targeted historical databases of DCS systems and older plant and process historians

bull Batch systems may have a mechanism to export batch recipes Recipes may require hand-mapping into target batch management application

Operator consoles (supervisory control and operations)

bull Console level interconnection between systems

bull Console tag database

bull Alarms and events

bull Standard displays

bull Custom graphics displays

bull Generally there is a defined mechanism for connecting and sharing information at the console level often via OPC technology

bull Export or extract console tags from the legacy system or console subsystem and autogenerate a tag database for the PlantPAx system

bull Establish alarms and events at the console level of the PlantPAx system or migrate to controller-based tags

bull Faceplates may be available to maintain the look-and-feel of the legacy DCS

bull Conversion utilities may be available to convert all or part of the legacy DCS operator graphics displays

Control Networks bull Controller-to-controller communications

bull Control layer-to-control layer communications

The PlantPAx system supports standard interfaces for direct data communication like Modbus ControlNet EtherNetIP networks

Tools may be available to allow functional interconnection between systems at the control layer

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PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

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PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD ltFEFF004700650062007200750069006b002000640065007a006500200069006e007300740065006c006c0069006e00670065006e0020006f006d0020005000440046002d0064006f00630075006d0065006e00740065006e0020007400650020006d0061006b0065006e00200064006900650020006700650073006300680069006b00740020007a0069006a006e0020006f006d0020007a0061006b0065006c0069006a006b006500200064006f00630075006d0065006e00740065006e00200062006500740072006f0075007700620061006100720020007700650065007200200074006500200067006500760065006e00200065006e0020006100660020007400650020006400720075006b006b0065006e002e0020004400650020005000440046002d0064006f00630075006d0065006e00740065006e0020006b0075006e006e0065006e00200077006f007200640065006e002000670065006f00700065006e00640020006d006500740020004100630072006f00620061007400200065006e002000520065006100640065007200200035002e003000200065006e00200068006f006700650072002egt ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 23: Selection Guide

PlantPAx Core System Chapter 2

Additional Resources

Controllers bull Control applications

bull Modular control applications

Tools are available to convert some legacy control system control application structures to PlantPAx structures

Where possible leverage the PlantPAx process engineering libraries for their use of PlantPAx features

IO bull IO connectivity

bull Smart Instruments

bull Cables to IO Terminations

bull IO Field Termination Units

bull There are IO scanner modules for some legacy DCS IO subsystems IO scanners communicate from PlantPAx communication modules to IO networks formerly connected to legacy DCS controllers

bull Legacy DCS systems may have made use of HART protocol Strong support for smart instrument and control device networks is available in standard PlantPAx functions

bull New cables connect legacy DCS field termination wiring to PlantPAx IO processing modules

Category Function Tools

Resource Description

httpwwwrockwellautomationcomsolutionsprocess

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

httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers

bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)

bull Rockwell Automation partner

bull 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

radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program

Publication PROCES-SG001A-EN-P - March 2009 23

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 24: Selection Guide

Chapter 2 PlantPAx Core System

Notes

24 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 25: Selection Guide

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

Section Page

DeviceNet Devices 26

HART Devices 28

Foundation Fieldbus Devices 30

Profibus PA Devices 32

Asset Management 35

25Publication PROCES-SG001A-EN-P - March 2009 25

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 26: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

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 configure and data collection capabilities for industrial devices

DeviceNet Products

ControlLogix

DeviceNet

1734 IO

SensorPush Buttons

CENTERLINE

EtherNetIP

Category Product Description

ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner

In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO

bull 1734-ADN adapter

bull 1734-ADNX adapter with subnet connectivity

bull 1734-PDN communication interface

1790 CompactBlock LDX IO Built-in adapter in base block

1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology

1794 FLEX IO 1794-ADN adapter

1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect to hazardous areas)

26 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 27: Selection Guide

PlantPAx Field Device Integration and Asset Management Chapter 3

Additional Resources

On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block

1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 Quick-Disconnect

terminations

bull 1738-ADN18 adapter with mini connector (drop)

bull 1738-ADN18P adapter with mini connector (pass-thru)

bull 1738-ADNX adapter with subnet connectivity

1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology

1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology

Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module

1762 MicroLogix expansion IO 1761-NET-DNI linking device

1769 Compact IO 1769-ADN adapter

1771 PLC-5 IO 1771-SDN module

XM condition monitoring specialty modules

1440 Emonitor Modules Built-in adapter

Motor control centers 2100 CENTERLINE Motor Control Centers

Built-in adapter

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components

POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001

1732 ArmorBlock and 1792 ArmorBlock IO modules

ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

httpwwwrockwellautomationcomencompass Encompass Program product directories

Publication PROCES-SG001A-EN-P - March 2009 27

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

28 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 28: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

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

HART Products

ControlLogix

ControlNet or EtherNetIP

FLEX IO

EtherNetIP

Category Product Description

Chassis-based IO modules 1756-IF8H1756-OF8H

ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

MVI56-HART Prosoft ControlLogix IO module

Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH

1797-IE8H1797-OE8H

FLEX and FLEX Ex analog IO modules withbull standard profiles in RSLogix 5000 software

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

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Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU ltFEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e0020005000440046002d0044006f006b0075006d0065006e00740065006e002c00200075006d002000650069006e00650020007a0075007600650072006c00e40073007300690067006500200041006e007a006500690067006500200075006e00640020004100750073006700610062006500200076006f006e00200047006500730063006800e40066007400730064006f006b0075006d0065006e00740065006e0020007a0075002000650072007a00690065006c0065006e002e00200044006900650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f0062006100740020006f0064006500720020006d00690074002000640065006d002000520065006100640065007200200035002e003000200075006e00640020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002egt FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 29: Selection Guide

PlantPAx Field Device Integration and Asset Management Chapter 3

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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Multiplexersgateways 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 HPSM32MM-01

5100 serial gateways

6000 wireless gateways

ProSoft gateways

Handheld devices SFX100 Field Xpert handheld device Endress+Hauser product

Category Product Description

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

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)

httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857

How to implement the HART Add-On-Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments

Publication PROCES-SG001A-EN-P - March 2009 29

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 30: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

Foundation Fieldbus Devices

Foundation Fieldbus 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

Foundation Fieldbus Products

ControlLogix

ControlNet

EtherNetIP1757-FFLDC

1757-FFLD

EtherNetIP

Category Product Description

EtherNetIP interface 1757FFLD21757-FFLD4

Bridge from an Ethernet network to either two or four H1 ports

ControlNet interface 1757-FFLDC21757-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-Ex4FF Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe terminator which screws into a 12 in NPT transmitter port

30 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

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Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

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Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

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PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

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Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

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Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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Page 31: Selection Guide

PlantPAx Field Device Integration and Asset Management Chapter 3

Foundation Fieldbus offers the ability for devices to share information among each other Control in the field is possible on 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs Foundation Fieldbus 360 mA 2527 V DC isolated power supply DIN rail

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Foundation Fieldbus H1 segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Foundation Fieldbus H1 segment

MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment

bull 2R two redundant segments

bull 4 four segments

bull 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 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software RSFieldbus software Configure Foundation Fieldbus devices

Category Product Description

Publication PROCES-SG001A-EN-P - March 2009 31

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 32: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

Additional Resources

Profibus PA Devices The Profibus (Process Field Bus) PA (Process Automation) network is the Profibus solution for process automation Profibus PA connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters Profibus PA is ideal for explosion-hazardous areas (Ex-zone 0 and 1)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

ControlLogix

EtherNetIP

EtherNetIP

32 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 33: Selection Guide

PlantPAx Field Device Integration and Asset Management Chapter 3

Profibus PA Products

Category Product Description

Profibus interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to Profibus PA linking device

Profibus network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 4 outputs 8 inputs intrinsically safe

DP-LBF-I134 Pepperl+Fuchs surge protection modules compatible with IEC 61158-2 DIN-rail mountable base and removable module

FN-FT-Ex1DIEC Pepperl+Fuchs Profibus PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port

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-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per Profibus PA segment

HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per Profibus PA segment

HD2-GTR-4PA Pepperl+Fuchs Profibus DPPA gateway 4 PA segments

MB-FB_GT Pepperl+Fuchs motherboard for simplex gateway

MB-FB_GTR Pepperl+Fuchs motherboard for redundant gateway

MB-FB-4GEN Pepperl+Fuchs power supply motherboard 4 segments

MB-FB-4RGEN Pepperl+Fuchs power supply motherboard 4 redundant segments

KT-MB-GTR-2PA Compact segment coupler kit - 2 PA segments -DPPA segment coupler and power modules and motherboard

Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to Profibus PA Mount inside cabinet Terminals for 46 810 and 12 spurs

SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available

F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs

Configuration software HSNetworxPA software HIPROM software for configuring Profibus PA devices

Publication PROCES-SG001A-EN-P - March 2009 33

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

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Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Page 34: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

Profibus PA device integration uses the 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

bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller

bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface

bull integration documentation that describes the implementation

Additional Resources

Resource Description

httpwwwrockwellautomationcomencompass Encompass Program product directories

httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml

Integration documents

34 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD ltFEFF004700650062007200750069006b002000640065007a006500200069006e007300740065006c006c0069006e00670065006e0020006f006d0020005000440046002d0064006f00630075006d0065006e00740065006e0020007400650020006d0061006b0065006e00200064006900650020006700650073006300680069006b00740020007a0069006a006e0020006f006d0020007a0061006b0065006c0069006a006b006500200064006f00630075006d0065006e00740065006e00200062006500740072006f0075007700620061006100720020007700650065007200200074006500200067006500760065006e00200065006e0020006100660020007400650020006400720075006b006b0065006e002e0020004400650020005000440046002d0064006f00630075006d0065006e00740065006e0020006b0075006e006e0065006e00200077006f007200640065006e002000670065006f00700065006e00640020006d006500740020004100630072006f00620061007400200065006e002000520065006100640065007200200035002e003000200065006e00200068006f006700650072002egt ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 35: Selection Guide

PlantPAx Field Device Integration and Asset Management Chapter 3

Asset Management Asset management adds to the core system components the functions for optimizing maintenance and plant operations This includes comprehensive diagnostics calibration real-time monitoring as well as auditing equipment and network health to improve overall resource availability

Computer Requirements - Application Server

Server Software - Asset Management

The asset management server provides a centralized system management for end field devices

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Asset management software bull FactoryTalk AssetCentre server software

bull FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software

bull Microsoft SQL Server 2000 software

Optional software bull IntelliCENTER software for motor control centers

Publication PROCES-SG001A-EN-P - March 2009 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Page 36: Selection Guide

Chapter 3 PlantPAx Field Device Integration and Asset Management

Notes

36 Publication PROCES-SG001A-EN-P - March 2009

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO ltFEFF004e00e4006900640065006e002000610073006500740075007300740065006e0020006100760075006c006c006100200076006f006900740020006c0075006f006400610020006a0061002000740075006c006f00730074006100610020005000440046002d0061007300690061006b00690072006a006f006a0061002c0020006a006f006900640065006e0020006500730069006b0061007400730065006c00750020006e00e400790074007400e400e40020006c0075006f00740065007400740061007600610073007400690020006c006f00700070007500740075006c006f006b00730065006e002e0020005000440046002d0061007300690061006b00690072006a0061007400200076006f0069006400610061006e0020006100760061007400610020004100630072006f006200610074002d0020006a0061002000520065006100640065007200200035002e00300020002d006f0068006a0065006c006d0061006c006c0061002000740061006900200075007500640065006d006d0061006c006c0061002000760065007200730069006f006c006c0061002egt ITA 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 37: Selection Guide

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management solutions enable you to develop cost-effective batch control strategies by supporting flexible production capabilities equipment independent recipes and batch-independent equipment control

Section Page

Controller-based Batch Sequencing 39

Controller-based Batch Management and Control 40

Chassis-based Batch Management and Control 41

Application Server Batch Management and Control 43

Material Management 45

37Publication PROCES-SG001A-EN-P - March 2009 37

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
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Page 38: Selection Guide

Chapter 4 PlantPAx Batch Management and Control

Rockwell Automation understands there are diverse batch processing needs simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing or any combination of these Each need requires a different recipe and process management and control approach

bull Solution optimized for fixed sequences fixed formulation and simple equipment control

bull Solution optimized for fixed sequences flexible formulation and simple equipment control

bull Solution optimized for flexible sequences flexible formulations multiple unit coordination

bull Solution optimized for flexible sequences flexible formulation multiple unit coordination and networked pathway coordination

In addition to this batch management amp control should also address other business and production functions as well These include

bull process monitoring and controlbull manufacturing operationsbull business and supply chain integrationbull information analysis and reportingbull regulation standards and best practicesbull security availability and data integritybull maintenance support and training

Understanding both process complexity and business and production functions is critical to defining the right solution to meet your demanding requirements

38 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 39: Selection Guide

PlantPAx Batch Management and Control Chapter 4

Controller-based Batch Sequencing

Controller-based sequencing 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

Controller-based Batch Sequencing Products

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Publication PROCES-SG001A-EN-P - March 2009 39

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 40: Selection Guide

Chapter 4 PlantPAx Batch Management and Control

Controller-based Batch Management and Control

Controller-based batch management and control solutions extend the core system Logix functionality (PhaseManager software) to provide basic batch management and control functionality in the controller This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible procedure definition without the overhead of more comprehensive serversoftware-based solutions PhaseManager software is the basis for process control code A controller-based batch engine provides recipe management information management process management and unit supervision

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control

Controller-based Batch Management and Control Products

You might also need a SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch control logic ControlLogix batch code extension Available as part of the process application toolkit

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

40 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode 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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 41: Selection Guide

PlantPAx Batch Management and Control Chapter 4

Chassis-based Batch Management and Control

Chassis-based batch management and control solutions combine the core system Logix functionality (PhaseManager software) with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the comprehensive batch management capability packaged in a local chassis module for small systems 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

Generally these solutions are optimized for skid-based flexible sequences flexible formulation and multiple unit coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

OWSEWS

Publication PROCES-SG001A-EN-P - March 2009 41

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA ltFEFF00550073006100720065002000710075006500730074006500200069006d0070006f007300740061007a0069006f006e00690020007000650072002000630072006500610072006500200064006f00630075006d0065006e007400690020005000440046002000610064006100740074006900200070006500720020006c00610020007300740061006d00700061002000650020006c0061002000760069007300750061006c0069007a007a0061007a0069006f006e006500200064006900200064006f00630075006d0065006e0074006900200061007a00690065006e00640061006c0069002e0020004900200064006f00630075006d0065006e00740069002000500044004600200070006f00730073006f006e006f0020006500730073006500720065002000610070006500720074006900200063006f006e0020004100630072006f00620061007400200065002000520065006100640065007200200035002e003000200065002000760065007200730069006f006e006900200073007500630063006500730073006900760065002egt NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 42: Selection Guide

Chapter 4 PlantPAx Batch Management and Control

Chassis-based Batch Management and Control Products

1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the ControlLogix chassis

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

In-chassis batch module 1756-SAM The Logix specialty application module is an in-chassis Windows-based computer on which the FactoryTalk Batch software is installed

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Infrastructure software bull FactoryTalk Services Platform client software

bull RSLinx Classic software

bull FactoryTalk Activation server software

42 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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ltFEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e0020005000440046002d0044006f006b0075006d0065006e00740065006e002c00200075006d002000650069006e00650020007a0075007600650072006c00e40073007300690067006500200041006e007a006500690067006500200075006e00640020004100750073006700610062006500200076006f006e00200047006500730063006800e40066007400730064006f006b0075006d0065006e00740065006e0020007a0075002000650072007a00690065006c0065006e002e00200044006900650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f0062006100740020006f0064006500720020006d00690074002000640065006d002000520065006100640065007200200035002e003000200075006e00640020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002egt FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 43: Selection Guide

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control

Application server batch management and control solutions leverage the core system Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) to provide batch management and control functionality This solution offers the user comprehensive batch management capability on a standard application server and can be scaled to meet increased requirements 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

Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination

Redundant Controller Pair

Distributed IO Racks

Foundation Fieldbus Links

Intrinsically Safe AreaClass 1 Div 1

ControlNet Links

Application Server - Batch ManagementOWSEWS

Publication PROCES-SG001A-EN-P - March 2009 43

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 44: Selection Guide

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Batch

The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch server can be given to the Windows Service Manager

You might also need abull material manager serverbull historian server for batch analysisbull SQL server for reporting and logging

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Batch software bull FactoryTalk Batch server

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

bull FactoryTalk eProcedure software (optional)

Process historian software bull FactoryTalk Historian Batch EVT Interface software (optional)

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

bull FactoryTalk Activation server

44 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 NOR 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 45: Selection Guide

PlantPAx Batch Management and Control Chapter 4

Application Server Batch Management and Control Products

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 which enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Category Product Description

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 160 non-redundant

controller

bull Firmware revision 165 redundant controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager and SFC language

Batch visualization FactoryTalk View batch visualization extension Available as part of the process application toolkit

Application Server - Batch Management

Application Server - Material Management

Controller and Field Device Interfaces

EtherNetIP

Link to Distributed IO

Publication PROCES-SG001A-EN-P - March 2009 45

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 46: Selection Guide

Chapter 4 PlantPAx Batch Management and Control

Computer Requirements - Application Server

Server Software - Material Manager

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

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third party software bull Microsoft SQL Server 2000 software (archival and web-based reporting)

bull NortonSymantec Antivirus software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 6 software

46 Publication PROCES-SG001A-EN-P - March 2009

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 47: Selection Guide

Chapter 5

PlantPAx Process Information

Introduction PlantPAx process information subsystems include an integrated set of decision-making tools and dashboards that provide real-time access to and analysis of process and production information throughout the enterprise These tools

bull provide process historian capabilitybull produce web-based KPI dashboards and reportsbull deliver timely information to appropriate personnel throughout

manufacturing ndash derived from various manufacturing processes

Section Page

Process Historian 48

Process Information and Decision Support 48

47Publication PROCES-SG001A-EN-P - March 2009 47

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 48: Selection Guide

Chapter 5 PlantPAx Process Information

Process Historian The process historian provides collection and storage of historical contextual data for some or all of the process information Process historian analytic tools can then be used to view and analyze this historical data

Computer Requirements - Application Server

Server Software - Process Historian

The process historian server supports real-time data collection

Process Information and Decision Support

The PlantPAx subsystem for process information and decision support provides access to all process and enterprise data sources and delivers timely web-based analyses visualizations and reports to process and business stake-holders This subsystem is comprised of FactoryTalk VantagePoint software on an enterprise management intelligence (EMI) server appropriate data source connectors and web-based thin clients Typical data sources include PlantPAx controllers historians databases (such as ORACLE and SQL) enterprise applications (such as SAP via R3 and Netweaver connectors) laboratory quality and maintenance systems batch and alarms and events systems and legacy (third-party) systems

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

Historian software bull FactoryTalk Historian server software

Infrastructure software bull FactoryTalk Services Platform server with Admin Console software

bull FactoryTalk Activation server software

48 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 49: Selection Guide

PlantPAx Process Information Chapter 5

Computer Requirements - Application Server

Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access to manufacturing and plant data sources and supports web-based reporting

Attribute Application Server

Computer hardware bull Pentium 4 dual core processor

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull Dedicated Ethernet card

bull UPS power backup recommended

Software Product

Operating system bull Windows 2003 Server operating system

EMI software bull FactoryTalk VantagePoint EMI software

Infrastructure software bull FactoryTalk Services Platform server software

bull RSLinx Classic software

bull FactoryTalk Activation server software

Supported third party software bull NortonSymantec Antivirus software

bull Adobe Acrobat Reader 80 software

bull Diskeeper software

bull NortonSymantec Ghost software

bull Microsoft Internet Explorer 7 software

bull Microsoft Internet IIS with WWW service

bull SQL Server 2005 software (can be remote)

Optional components bull MS Office 2007 software

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

Publication PROCES-SG001A-EN-P - March 2009 49

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 50: Selection Guide

Chapter 5 PlantPAx Process Information

Notes

50 Publication PROCES-SG001A-EN-P - March 2009

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 NLD 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 ESP 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 51: Selection Guide

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 objectives - cost reductions decreased emissions consistent quality and production increases - every 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

2533

3950

6470

92

115

66 1100 13

25253333

39395050

646470

9292

115

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

51Publication PROCES-SG001A-EN-P - March 2009 51

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 NLD ltFEFF004700650062007200750069006b002000640065007a006500200069006e007300740065006c006c0069006e00670065006e0020006f006d0020005000440046002d0064006f00630075006d0065006e00740065006e0020007400650020006d0061006b0065006e00200064006900650020006700650073006300680069006b00740020007a0069006a006e0020006f006d0020007a0061006b0065006c0069006a006b006500200064006f00630075006d0065006e00740065006e00200062006500740072006f0075007700620061006100720020007700650065007200200074006500200067006500760065006e00200065006e0020006100660020007400650020006400720075006b006b0065006e002e0020004400650020005000440046002d0064006f00630075006d0065006e00740065006e0020006b0075006e006e0065006e00200077006f007200640065006e002000670065006f00700065006e00640020006d006500740020004100630072006f00620061007400200065006e002000520065006100640065007200200035002e003000200065006e00200068006f006700650072002egt ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 52: Selection Guide

Chapter 6 PlantPAx Plantwide Optimization

Computer Requirements - Pavilion Platform

Software - Pavilion Platform

The Pavilion platform supports model predictive control environmental performance management and production performance management

Attribute Application Server

Client hardware bull Pentium III processor

bull 500 MHz CPU

bull 025 GB memory

bull 05 GB disk space

Application server hardware

bull Pentium 4 processor

bull 24 GHz CPU

bull 24 GB memory

bull 40 GB disk space

Control application hardware

bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

bull 40 GB disk space

Software Product

Client bull Windows 2003 Server operating system

bull Internet Explorer 60 software with Service Pack 1

Application sever bull Windows 2000 Windows XP or Windows 2003 Server operating system

bull Console Service software

bull Pavilion Data Access Service (PDAS) software

Control application bull Windows 2000 or Windows XP operating system

bull Pavilion 8 Model Predictive Control software

52 Publication PROCES-SG001A-EN-P - March 2009

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 53: Selection Guide

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

Section Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL2 and SIL 3 Systems 58

53Publication PROCES-SG001A-EN-P - March 2009 53

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 54: Selection Guide

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability in order tobull maintain productionbull protect against equipment or product lossesbull 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

54 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD ltFEFF004700650062007200750069006b002000640065007a006500200069006e007300740065006c006c0069006e00670065006e0020006f006d0020005000440046002d0064006f00630075006d0065006e00740065006e0020007400650020006d0061006b0065006e00200064006900650020006700650073006300680069006b00740020007a0069006a006e0020006f006d0020007a0061006b0065006c0069006a006b006500200064006f00630075006d0065006e00740065006e00200062006500740072006f0075007700620061006100720020007700650065007200200074006500200067006500760065006e00200065006e0020006100660020007400650020006400720075006b006b0065006e002e0020004400650020005000440046002d0064006f00630075006d0065006e00740065006e0020006b0075006e006e0065006e00200077006f007200640065006e002000670065006f00700065006e00640020006d006500740020004100630072006f00620061007400200065006e002000520065006100640065007200200035002e003000200065006e00200068006f006700650072002egt ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 55: Selection Guide

PlantPAx Critical Process Control and Safety Systems Chapter 7

High Availability Products

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 meet growing standards compliance requirements worldwide

The SIL 2 TYPE certification of ControlLogix controllers assures the suitability of ControlLogix products for use in safety applications up to and including SIL 2

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revision 165

bull Redundant Add-On Instructions

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)

bull 1757-SRM

Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F

bull 1756-ENBT

ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

IO interface (downlink) bull 1756-CN2 1756-CN2R

bull 1756-CNB 1756-CNBR

Severs and workstations Redundant process automation system server (PASS)

Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover

bull FactoryTalk Live Data services

Publication PROCES-SG001A-EN-P - March 2009 55

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
                                                                                                                        • ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles false AutoRotatePages None Binding Left CalGrayProfile (Gray Gamma 22) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (Euroscale Uncoated v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket true DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 99 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo false PreserveCopyPage true 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 PTB 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 NLD 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 ESP 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 SUO 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 ITA ltFEFF00550073006100720065002000710075006500730074006500200069006d0070006f007300740061007a0069006f006e00690020007000650072002000630072006500610072006500200064006f00630075006d0065006e007400690020005000440046002000610064006100740074006900200070006500720020006c00610020007300740061006d00700061002000650020006c0061002000760069007300750061006c0069007a007a0061007a0069006f006e006500200064006900200064006f00630075006d0065006e0074006900200061007a00690065006e00640061006c0069002e0020004900200064006f00630075006d0065006e00740069002000500044004600200070006f00730073006f006e006f0020006500730073006500720065002000610070006500720074006900200063006f006e0020004100630072006f00620061007400200065002000520065006100640065007200200035002e003000200065002000760065007200730069006f006e006900200073007500630063006500730073006900760065002egt NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 56: Selection Guide

Chapter 7 PlantPAx Critical Process Control and Safety Systems

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 EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A

Remote IO Chassis B

ControlNet or EtherNetIP Network

1492 Termination Board

Sensor

Actuator

Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop

56 Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB ltFEFF005500740069006c0069007a006500200065007300740061007300200063006f006e00660069006700750072006100e700f5006500730020007000610072006100200063007200690061007200200064006f00630075006d0065006e0074006f0073002000500044004600200063006f006d00200075006d0061002000760069007300750061006c0069007a006100e700e3006f0020006500200069006d0070007200650073007300e3006f00200061006400650071007500610064006100730020007000610072006100200064006f00630075006d0065006e0074006f007300200063006f006d0065007200630069006100690073002e0020004f007300200064006f00630075006d0065006e0074006f0073002000500044004600200070006f00640065006d0020007300650072002000610062006500720074006f007300200063006f006d0020006f0020004100630072006f006200610074002c002000520065006100640065007200200035002e00300020006500200070006f00730074006500720069006f0072002egt DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 57: Selection Guide

PlantPAx Critical Process Control and Safety Systems Chapter 7

Fail Safe Configuration

Additional Resources

For SIL applications a programming terminal is not normally connected

SIL-2 certified ControlLogix components are within the overall safety loopSensor

Actuator

Plantwide Ethernet or Serial Network

Overall Safety Loop

ControlNet or EtherNetIP Network

Connect to other safety-related ControlLogix and other remote IO chassis

ControlNet or EtherNetIP 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)

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001

ControlLogix components supported in SIL 2 configurations

httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications

Publication PROCES-SG001A-EN-P - March 2009 57

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 58: Selection Guide

Chapter 7 PlantPAx Critical Process Control and Safety Systems

ICS Triplex SIL2 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

ICS Triplex Products

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company

Additional Resource

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

Category Product Description

ICS Triplex control system Trusted systems 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 systems The AADvance technology isbull configurable for SIL 1 SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

bull integration via OPC or CIP protocols

Resource Description

httpwwwicstriplexcom ICS Triplex a Rockwell Automation company products

58 Publication PROCES-SG001A-EN-P - March 2009

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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ltFEFF004f007000740069006f006e00730020007000650072006d0065007400740061006e007400200064006500200063007200e900650072002000640065007300200064006f00630075006d0065006e007400730020005000440046002000700072006f00660065007300730069006f006e006e0065006c007300200066006900610062006c0065007300200070006f007500720020006c0061002000760069007300750061006c00690073006100740069006f006e0020006500740020006c00270069006d007000720065007300730069006f006e002e00200049006c002000650073007400200070006f0073007300690062006c0065002000640027006f00750076007200690072002000630065007300200064006f00630075006d0065006e007400730020005000440046002000640061006e00730020004100630072006f0062006100740020006500740020005200650061006400650072002c002000760065007200730069006f006e002000200035002e00300020006f007500200075006c007400e9007200690065007500720065002egt PTB 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 59: Selection Guide

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 sense - delivering maximum value without relying on proprietary hardware and software

Domain Controller The domain controller is a separate computer The domain controller must be local to the workstations and servers and not remote to the system 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

Computer Requirements - Domain Controller

Section Page

Domain Controller 59

Ethernet Hardware 60

System Software and Services 60

Attribute Domain Controller

Hardware bull Pentium processor

bull 20 GHz CPU

bull 1 GB memory

Software bull Windows 2003 server

bull No application software

Configuration bull Hyper-threading optional

bull DHCP enabled with IP address reservation

bull Active directory

bull Kerberos authentication protocol

bull DNS server

bull WINS server

bull No routing

bull No firewall

bull No power management

bull No screen saver

59Publication PROCES-SG001A-EN-P - March 2009 59

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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ltFEFF004200720075006700200064006900730073006500200069006e0064007300740069006c006c0069006e006700650072002000740069006c0020006100740020006f0070007200650074007400650020005000440046002d0064006f006b0075006d0065006e007400650072002c0020006400650072002000650072002000650067006e006500640065002000740069006c0020007000e5006c006900640065006c006900670020007600690073006e0069006e00670020006f00670020007500640073006b007200690076006e0069006e006700200061006600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e007400650072006e00650020006b0061006e002000e50062006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt NLD 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 ESP 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 SUO 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 ITA ltFEFF00550073006100720065002000710075006500730074006500200069006d0070006f007300740061007a0069006f006e00690020007000650072002000630072006500610072006500200064006f00630075006d0065006e007400690020005000440046002000610064006100740074006900200070006500720020006c00610020007300740061006d00700061002000650020006c0061002000760069007300750061006c0069007a007a0061007a0069006f006e006500200064006900200064006f00630075006d0065006e0074006900200061007a00690065006e00640061006c0069002e0020004900200064006f00630075006d0065006e00740069002000500044004600200070006f00730073006f006e006f0020006500730073006500720065002000610070006500720074006900200063006f006e0020004100630072006f00620061007400200065002000520065006100640065007200200035002e003000200065002000760065007200730069006f006e006900200073007500630063006500730073006900760065002egt NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 60: Selection Guide

Chapter 8 PlantPAx Infrastructure

Ethernet Hardware Infrastructure components that integrate enterprise manufacturing and plant floor environments include Ethernet switches

System Software and Services

System software and services are used across all of the system components

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 topologiesbull Stratix 8000 modular managed switches

bull Stratix 6000 fixed managed switches

bull Stratix 2000 unmanaged switches

Cisco switches Supervisory switches at higher levels of the process system include the Cisco Catalyst 2950 series managed switch

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 controlbull One place to create grant rights and monitor all users of the system

bull Simplification of regulatory compliance

bull 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 productbull No activation media to manage

bull Simple method for obtaining a floating or borrowed license

bull 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 systembull Consistent user interface for visualization and management across the entire system

bull Virtually no HMI alarm configuration required

bull 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 displaysbull Define it once use it everywhere and do not duplicate

bull Logical naming eases redeployment of physical servers

bull No central database no single point of failure

60 Publication PROCES-SG001A-EN-P - March 2009

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 61: Selection Guide

Notes

61Publication PROCES-SG001A-EN-P - March 2009 61

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
                                                                                                                        • ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles false AutoRotatePages None Binding Left CalGrayProfile (Gray Gamma 22) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (Euroscale Uncoated v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket true DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 99 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo false PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP ltFEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200071007500650020007000650072006d006900740061006e002000760069007300750061006c0069007a006100720020006500200069006d007000720069006d0069007200200063006f007200720065006300740061006d0065006e0074006500200064006f00630075006d0065006e0074006f007300200065006d00700072006500730061007200690061006c00650073002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 62: Selection Guide

Notes

62 Publication PROCES-SG001A-EN-P - March 2009

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
                                                                                                                        • ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles false AutoRotatePages None Binding Left CalGrayProfile (Gray Gamma 22) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (Euroscale Uncoated v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket true DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 99 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo false PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 NLD 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 ESP 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 SUO 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 ITA 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 NOR ltFEFF004200720075006b00200064006900730073006500200069006e006e007300740069006c006c0069006e00670065006e0065002000740069006c002000e50020006f00700070007200650074007400650020005000440046002d0064006f006b0075006d0065006e00740065007200200073006f006d002000700061007300730065007200200066006f00720020007000e5006c006900740065006c006900670020007600690073006e0069006e00670020006f00670020007500740073006b007200690066007400200061007600200066006f0072007200650074006e0069006e006700730064006f006b0075006d0065006e007400650072002e0020005000440046002d0064006f006b0075006d0065006e00740065006e00650020006b0061006e002000e50070006e006500730020006d006500640020004100630072006f0062006100740020006f0067002000520065006100640065007200200035002e00300020006f0067002000730065006e006500720065002egt SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 63: Selection Guide

Notes

Publication PROCES-SG001A-EN-P - March 2009 63

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products At httpsupportrockwellautomationcom 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 httpsupportrockwellautomationcom

Installation Assistance

If you experience a problem within the first 24 hours of installation please review the information thats contained in this manual You can also contact a special Customer Support number 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

United States 14406463434Monday ndash Friday 8am ndash 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues

United States Contact your distributor You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor in order to complete the return process

Outside United States

Please contact your local Rockwell Automation representative for the return procedure

  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
                                                                                                                        • ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles false AutoRotatePages None Binding Left CalGrayProfile (Gray Gamma 22) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (Euroscale Uncoated v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket true DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 99 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo false PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo false PreserveFlatness true PreserveHalftoneInfo true PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Preserve UsePrologue false ColorSettingsFile (None) AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 150 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Bicubic ColorImageResolution 150 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 100000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 150 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Bicubic GrayImageResolution 150 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 100000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 900 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Bicubic MonoImageResolution 900 MonoImageDepth -1 MonoImageDownsampleThreshold 100000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects true CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName (httpwwwcolororg) PDFXTrapped False SyntheticBoldness 1000000 Description ltlt JPN ltFEFF3053306e8a2d5b9a306f300130d330b830cd30b9658766f8306e8868793a304a3088307353705237306b90693057305f00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e30593002gt DEU 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 FRA 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 PTB 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 DAN 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 NLD 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 ESP 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 SUO ltFEFF004e00e4006900640065006e002000610073006500740075007300740065006e0020006100760075006c006c006100200076006f006900740020006c0075006f006400610020006a0061002000740075006c006f00730074006100610020005000440046002d0061007300690061006b00690072006a006f006a0061002c0020006a006f006900640065006e0020006500730069006b0061007400730065006c00750020006e00e400790074007400e400e40020006c0075006f00740065007400740061007600610073007400690020006c006f00700070007500740075006c006f006b00730065006e002e0020005000440046002d0061007300690061006b00690072006a0061007400200076006f0069006400610061006e0020006100760061007400610020004100630072006f006200610074002d0020006a0061002000520065006100640065007200200035002e00300020002d006f0068006a0065006c006d0061006c006c0061002000740061006900200075007500640065006d006d0061006c006c0061002000760065007200730069006f006c006c0061002egt ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 64: Selection Guide

64 Publication PROCES-SG001A-EN-P - March 2009

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

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  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 DAN 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 ESP 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 SUO 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 ITA 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 NOR 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 SVE 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 ENU (Rockwell Job Options for Web-only PDF Files) gtgtgtgt setdistillerparamsltlt HWResolution [2540 2540] PageSize [792000 1224000]gtgt setpagedevice

Page 65: Selection Guide

Publication PROCES-SG001A-EN-P - March 2009 65 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA

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  • PROCES-SG001A-EN-P PlantPAx Process Automation System Selection Guide
  • Table of Contents
  • 1 - PlantPAx Process Automation System Overview
    • Introduction
    • Architecture Classes
    • Independent Class Architecture Example
    • Centralized Class Architecture Example
    • Distributed Class Architecture Example
    • Recommended Architecture Sizes
      • 2 - PlantPAx Core System
        • Introduction
        • Core Control Hardware
          • Control Hardware
          • Additional Resources
            • Core Servers and Workstations
              • Computer Requirements - Workstations and Servers
              • Server Software - PASS
              • Workstation Software - EWS
              • Workstation Software - OWS
              • Independent Workstation
                • Engineering Tools
                • Migration Tools and Services
                  • Migration Tools
                  • Additional Resources
                      • 3 - PlantPAx Field Device Integration and Asset Management
                        • Introduction
                        • DeviceNet Devices
                          • DeviceNet Products
                          • Additional Resources
                            • HART Devices
                              • HART Products
                              • Additional Resources
                                • Foundation Fieldbus Devices
                                  • Foundation Fieldbus Products
                                  • Additional Resources
                                    • Profibus PA Devices
                                      • Profibus PA Products
                                      • Additional Resources
                                        • Asset Management
                                          • Computer Requirements - Application Server
                                          • Server Software - Asset Management
                                              • 4 - PlantPAx Batch Management and Control
                                                • Introduction
                                                • Controller-based Batch Sequencing
                                                  • Controller-based Batch Sequencing Products
                                                    • Controller-based Batch Management and Control
                                                      • Controller-based Batch Management and Control Products
                                                        • Chassis-based Batch Management and Control
                                                          • Chassis-based Batch Management and Control Products
                                                          • 1756-SAM Module Software - Batch
                                                            • Application Server Batch Management and Control
                                                              • Computer Requirements - Application Server
                                                              • Server Software - Batch
                                                              • The batch server integrates process devices (such as Logix5000 controllers) and third-party software packages The batch server operates as a Windows service which means the batch server can start automatically and that control of the batch
                                                              • Application Server Batch Management and Control Products
                                                                • Material Management
                                                                  • Computer Requirements - Application Server
                                                                  • Server Software - Material Manager
                                                                      • 5 - PlantPAx Process Information
                                                                        • Introduction
                                                                        • Process Historian
                                                                          • Computer Requirements - Application Server
                                                                          • Server Software - Process Historian
                                                                            • Process Information and Decision Support
                                                                              • Computer Requirements - Application Server
                                                                              • Server Software - Enterprise Management Intelligence
                                                                                  • 6 - PlantPAx Plantwide Optimization
                                                                                    • Introduction
                                                                                      • Computer Requirements - Pavilion Platform
                                                                                      • Software - Pavilion Platform
                                                                                          • 7 - PlantPAx Critical Process Control and Safety Systems
                                                                                            • Introduction
                                                                                            • High Availability Systems
                                                                                              • High Availability Products
                                                                                                • ControlLogix SIL 1 and SIL 2 Systems
                                                                                                  • Fault Tolerant Configuration
                                                                                                  • Fail Safe Configuration
                                                                                                  • Additional Resources
                                                                                                    • ICS Triplex SIL2 and SIL 3 Systems
                                                                                                      • ICS Triplex Products
                                                                                                      • Additional Resource
                                                                                                          • 8 - PlantPAx Infrastructure
                                                                                                            • Introduction
                                                                                                            • Domain Controller
                                                                                                              • Computer Requirements - Domain Controller
                                                                                                                • Ethernet Hardware
                                                                                                                • System Software and Services
                                                                                                                  • Notes
                                                                                                                  • Installation Assistance
                                                                                                                  • New Product Satisfaction Return
                                                                                                                      • Back Cover
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 FRA 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 PTB 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 ITA 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 NOR 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