selection guide
DESCRIPTION
AB Plant Pax Selection GuideTRANSCRIPT
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
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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
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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)
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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
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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
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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)
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
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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
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Notes
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Notes
Publication PROCES-SG001A-EN-P - March 2009 63
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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
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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
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Outside United States
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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
-
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
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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
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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
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
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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
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
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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
-
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
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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
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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
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
-
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
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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
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
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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
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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
-
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
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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
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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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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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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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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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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
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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
62 Publication PROCES-SG001A-EN-P - March 2009
Notes
Publication PROCES-SG001A-EN-P - March 2009 63
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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
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
-
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
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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
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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
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
-
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
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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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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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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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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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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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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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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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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
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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
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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
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
-
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)
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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
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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
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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
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
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
-
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)
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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
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
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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
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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
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
-
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
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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
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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
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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
-
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
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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
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
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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
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
-
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)
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
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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
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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
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
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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
-
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
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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
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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
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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
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
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
-
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
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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
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
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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
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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
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
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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
-
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
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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
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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
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
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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
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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
-
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
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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
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
-
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
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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
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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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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
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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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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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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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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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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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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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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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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
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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
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
-
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
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
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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
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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
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
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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
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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
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
-
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
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
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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
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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
-
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
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
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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
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Notes
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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
-
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
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
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
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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
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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
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
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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
-
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
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
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
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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
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
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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
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
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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
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
-
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
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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
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
-
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
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
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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
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
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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
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
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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
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Notes
Publication PROCES-SG001A-EN-P - March 2009 63
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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
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
-
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
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
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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
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
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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
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
-
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
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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
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
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
-
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
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
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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
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
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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
-
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
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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
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
-
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
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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
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
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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
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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
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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
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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
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
-
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
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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
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
-
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
-
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
-
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
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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
-
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
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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
-
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
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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
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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
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
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
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
-
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
-
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
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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
-
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
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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
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-