proces sg001 en p plantpax2 selectionguide

Selection Guide

PlantPAx Process Automation SystemSystem Release 2.0

Selection Guide Scope

The PlantPAx Process Automation System is a defined set of standard Rockwell Automation Integrated Architecture products that are configured in a prescribed way to provide optimal performance as a process automation system. When combining PlantPAx core system components, tools, and utilities, with other Rockwell Automation and partners products, the result is unmatched automation system flexibility, scalability, and expandability when solving continuous batch as well as high-speed discrete applications. This PlantPAx Selection Guide is used to assist with equipment procurement after you have defined your system requirements.Figure 1 - Selection Guide Scope

Define & Procure

System Setup & Configuration C n

Application Specific Code

System Test

C Commission n

Support

PlantPAx System Overview Core System Definition Field Device Integration Batch Management Process Information Advanced Process High Availability Critical Process Infrastructure Migration Selection Guide32238-MC

You do not need to read the sections in sequential chapter order. If you already have selected core elementsfor example, defining the computer hardware and operating systemyou can skip to other sections, such as PlantPAx infrastructure requirements or the types of process instrumentation on your network. You can view or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

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Rockwell Automation Publication PROCES-SG001D-EN-P - December 2011


What's New?

PlantPAx system release 2.0 improves on existing capabilities to further strengthen our ability for plant-wide optimization. These latest generation features are described in the table.Description High availability is a critical attribute of the PlantPAx system, and weve added significant flexibility and scalability without unnecessary investment. The additional capabilities include the following: Device Level Ring network topologies, which provide a highly available EtherNet/IP network without added cost for additional switches and infrastructure. New redundant I/O modules with redundant controller support for remote I/O on an EtherNet/IP network. Single-fault tolerance for native and third-party controllers by using alarm and events service. Enhanced diagnostic and error checking on the supervisory layer. Ability to import large changes into a running controller without disrupting the non-effected logic. Ability to edit a sequential function chart online without resetting the chart to its initial step. The PlantPAx system has expanded its offerings for connectivity options for communication protocols, including HART, FOUNDATION Fieldbus, and PROFIBUS PA. These are examples: HART solution includes higher density (16-channel) and lower density (2-channel) modules. PROFIBUS PA now also supports redundant linking devices. Fieldbus has new configuration software and a DTM that allows devices supporting only the EDDL environment to be configured and maintained via the PlantPAx asset management suite. Asset management tools also are integrated for intelligent motor control centers, variable frequency drives, condition monitoring, and power control components.

PlantPAx Process Automation System System high availability

Device integration and asset management

Design productivity

Careful evaluation of the typical DCS configuration workflows has allowed us to address steps that can be simplified or accelerated. These include the following: Initial sizing, architecture design, and documentation to make sure overall system performance meets or exceeds market expectations. Expanded PlantPAx library provides more reusable engineering, template objects, and diagnostics. Engineering and deployment tools that minimize human error prior to checkout and testing. A wider offering to meet diverse batch requirements includes batch and sequencing control for small, medium, to large plants. For simpler requirements, our new Logix Batch and Sequence Manager offers simple configuration and execution and easily integrates into a higher-level batch strategy for future growth. For more complex levels, the batch server software adds key capabilities, such as intelligent recipes, improved runtime user control, expanded data collection and reporting, and enhanced material management. A data management and analysis system to complement any plant size. FactoryTalk Historian collects and records data locally in the controller chassis, at the site level, or even larger solutions. Collected data is analyzed and reported to the appropriate user role, such as maintenance or control operators. The data also is reviewed for optimization to help deliver reliable production and economic gains. The CompactLogix controller platform offers a PlantPAx solution for skid equipment or turn-key systems in traditional process applications. This initiative introduces a set of architectures and efficiency tools to not only help equipment manufacturers deliver their scope quicker, but also offers the end-user simpler integration to, and more consistency with, their PlantPAx process automation system.

Batch and sequencing control

Operations productivity

OEM-sized architecture


3


Additional ResourcesResource

These documents contain additional information concerning related products from Rockwell Automation.

Table 1 - Additional DocumentationDescription Contains specifications for ControlLogix controllers. Provides recommendations for implementing a PlantPAx Process Automation system. Explains the infrastructure components that allow this open network to communicate seamlessly throughout a plant, from shop floor to top floor. Provides collaborative design guidelines based on the Cisco Ethernet-to-the-Factory solution and the Rockwell Automation Integrated Architecture solution. Explains the infrastructure components that allow this open network to communicate seamlessly throughout a plant, from shop floor to top floor. Describes the ControlNet network media components.

1756 ControlLogix Controllers Technical Data, publication 1756-TD001 PlantPAx Process Automation System Reference Manual, publication PROCES-RM001 EtherNet Design Considerations Reference Manual, publication ENET-RM002 Converged Plantwide EtherNet (CPwE) Design and Implementation Guide, publication ENET-TD001 Ethernet Design Considerations Reference Manual, publication ENET-RM002 ControlNet Media System Components List, publication AG-PA002

4


Table of ContentsChapter 1 PlantPAx System OverviewProcess System Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Architecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 EtherNet/IP Control Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 11 ControlNet Control Architecture Example . . . . . . . . . . . . . . . . . . . . . . . . 11 Recommended Architecture Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2 Core System DefinitionPlantPAx System Release 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Core Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant Networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Core Servers and Workstations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Automation System Server (PASS) . . . . . . . . . . . . . . . . . . . . . HMI Application Server (AppServ-HMI) . . . . . . . . . . . . . . . . . . . . . . Engineering Workstation (EWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Workstation (OWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skid-based Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineering Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 14 16 17 18 18 19 20 20 21 21 22 23 24 25

Chapter 3 Field Device Integration and Asset ManagementEtherNet/IP Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlNet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DeviceNet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HART Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOUNDATION Fieldbus Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROFIBUS PA Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asset Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asset Management Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 29 30 31 32 33 34 34 34

Chapter 4 Batch Management and Control Basic Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Basic Coded (custom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comprehensive Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-chassis Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batch High Availability Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication PROCES-SG001D-EN-P - December 2011

37 37 38 38 39 40 415

Table of Contents

Chapter 5 Process InformationData Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Decision Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Information Management Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 6 Advanced Process ControlAdvanced Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuzzy Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Predictive Control and Real-time Optimization . . . . . . . . . . . . . . 48 49 49 49

Chapter 7 High Availability SystemsHigh Availability Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 High Availability Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 8 Critical Process Control and Safety SystemsProcess Control Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlLogix SIL 1 and SIL 2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Tolerant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail Safe Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIL Rated Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ICS Triplex SIL 2 and SIL 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 56 57 58 58 59 59

Chapter 9 PlantPAx InfrastructureDomain Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Ethernet Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 10 Migration ToolsMigration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6


Chapter

1

PlantPAx System Overview

The PlantPAx system represents the Rockwell Automation culmination of significant investment in automation technology as it applies to the process industry. The PlantPAx system unifies core Integrated Architecture process automation capabilities and technologies with those of market leading partners under a common systems and solutions umbrella to provide a scalable, open, and cost-effective process solution.WAN / Enterprise

Level 5 Enterprise Business Planning

Patch Management Server

Remote Access Terminal Server

Production Workstation (PWS) Level 3/4 Site Manufacturing OperationsProduction Printers

DMZ

Production Clients

Application Server Asset Centre

Application Server Historian

Core System Field Device Integration / Asset Management Batch Management & Control Process Information Critical Process Control & Process Safety

100 MB EtherNet/IP Site / Plant Network

Level 2 Supervisory Control

System Printers

Engineering Workstation (EWS) DomainController

Process Automation System Server (PASS)

Operator Workstation (OWS)

Application Application Server Batch Server Material Management Management

Optional Safety System Development Workstation (IsaGraph)

100 MB EtherNet/IP Site / Plant Network

Redundant Controller Pair Level 1 Process Control Continuous/ BatchLocal Operator Workstation

Controller and Local I/O

Controller and Field Network BridgesEthernet I/O Remote I/O Down Link To non-safety related systems SIL 2 Controller with Fault Tolerant I/O

TMR SIL 3 Safety Controller and I/O

Maintenance Workstation MWS

Remote I/O

Remote I/O Racks

SIL 2 Safety Controller Fault Tolerant IO

DeviceNet

Motor Control Center (MCC)

1400 Termination BoardProfibus PA Foundation Fieldbus HI

Level 0 Field Devices/ Process

Foundation Fieldbus HI

Foundation Fieldbus HI Classic I/O / HART XM Condition Monitoring Classic I/O / HART

REDUNDANT COAX BARRIER

CNet Barrier

Foundation Fieldbus HI

In

Channel A

In

Channel B

InteliCENTER(Smart Motor Control Center)

COMM

STATUS

Intrinsically Safe Area Class 1 Div 1 Intrinsically Safe Area Class 1 Div 1

Field Device Networks Process Control HART Foundation Fieldbus Profibus PA Industrial Control DeviceNet EtherNet/IP ASI

31953-MC


7

Chapter 1


The PlantPAx system focuses on these main areas.Table 1 - PlantPAx System Focus AreasFocus Area Core system Description The core system includes the Integrated Architecture components common to all PlantPAx systems.The PlantPAx core system consists of the following: Engineering development environment (development tools) System-wide visualization (HMI components) Multi-disciplined process control (control hardware) In addition to supporting an extensive range of I/O products, the PlantPAx system supports integration with these components: Field devices, such as HART, FOUNDATION Fieldbus, and PROFIBUS PA, for process instrumentation. DeviceNet, ControlNet, and EtherNet/IP industrial control devices. These interfaces provide in-depth integration when used with our device integration tools developed through our partnership with Endress+Hauser for process instrumentation and drives and motor controls from Rockwell Automation. Asset management capabilities include code management, vibration monitoring, and device management. The PlantPAx system enables flexible production, equipment-independent recipe management, batch-independent equipment control, and support for regulatory compliance. These solutions are scalable and leverage industry standards to meet small, basic batch and sequencing needs, as well as distributed, comprehensive batch and sequencing needs. An integrated set of decision-making tools and dashboards provide real-time access to and analysis of process and production information throughout the enterprise: Produce web-based KPI dashboards and reports. Deliver timely information to appropriate personnel throughout manufacturingderived from various manufacturing processes. A distributed, historical data management strategy offers localized, chassis-based, high-speed data collection and recording, as well as site and enterprise solutions to meet the most demanding requirements. The PlantPAx system supports scalable solutions that meet specific requirements for availability and safety. ControlLogix controllers support SIL 1 and SIL 2 requirements. GuardLogix controllers support SIL 3 requirements. ICS Triplex Trusted controllers support triple modular redundancy and the scalable AADvance controllers support SIL 1, 2, and 3 capabilities in simplex, duplex, or triplex configurations. All of the ICS Triplex solutions are CIP-enabled and part of the Rockwell Automation Integrated Architecture. The PlantPAx system integrates with Pavilion8 software for predictive control, environmental performance management, and production performance management. Infrastructure components are standard network products (such as Ethernet media and switches) that are based on open industry standards and provide EtherNet/IP connectivity between Integrated Architecture components, as well as connectivity to higher level business systems.

Field device integration and asset management

Batch management and control

Process information

Critical process control and safety systems

Plantwide optimization Infrastructure

8



Chapter 1

Process System ElementsTable 2 - System ElementsSystem Element Process automation system server (PASS)

A PlantPAx system is built on these system elements (combinations of hardware and software products).

Description The PASS is a required system element that provides central name resolution and look up services. The PASS hosts a FactoryTalk View HMI server and an RSLinx Enterprise data server. The PASS also contains software components for alarms and events. The OWS provides an interactive graphical interface to monitor and control the process. The EWS provides a single development platform for creating and maintaining control strategies and for configuring system elements. The EWS is also a central storage location for configuration management. The batch application server can be an in-chassis or separate computer that runs FactoryTalk Batch software to provide batch management, information management, process management, and unit supervision. The information management server is the central data point for process information. The information management server supports both data management and decision support and support data analysis from the server. The asset management server provides a centralized location to manage end field devices. HMI application servers provide additional system capacity, as needed. The number of servers depends on the operational areas of the plant, as well as the number of these components: Controllers Alarms, displays, data logs, and historian tags Operator workstations The ControlLogix controller supports continuous process applications, including Advanced Process Control functions, with its deterministic, time-based execution mode. The controller supports continuous, batch, discrete, and motion applications. Physical location and controller loading affects the number of controllers needed in a PlantPAx system. Each controller supports a specified number of field device interfaces. Each controller has the capacity for a specific number of control strategies, which can be estimated based on the type of I/O connected to a controller. In an independent class architecture, the independent workstation (IndWS) combines the rolls of the PASS, OWS, and EWS all in one computer.

Operator workstation (OWS) Engineering workstation (EWS)

AppServ-Batch

AppServ-Information Management

AppServ-Asset Management AppServ-HMI

Controller

Independent workstation (IndWS)


9

Chapter 1


Architecture Classes

Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture. Rockwell Automation characterizes a process automation system based on its scope or architecture class. Architecture classes define system capabilities that can be scaled by modifying the same system elements: Independent system architecture for unit control Centralized system architecture for area control Distributed system architecture for plant-wide and enterprise operationsDistributed

Centralized Independent

Multiple Servers/ Multiple Clients Single Server/ Multiple Clients Single Server/ Single Client

Table 3 - Architecture ClassesArchitecture Independent Centralized Description An independent class architecture uses a single computer to perform PASS, EWS, and OWS functions. The centralized system is a multi-client configuration that supports the concept of automating a single production or process area. The system elements can provide main control room operation and enable you to mount operator workstations locally throughout the production facility. The centralized system expands the independent system by adding workstations and controllers. System Elements One independent workstation One dedicated PASS One dedicated EWS for the development and maintenance of the full system, including system security As many as eight OWS for the interactive graphical interface Application servers for batch management, data acquisition (historian), or change management (asset management) One dedicated PASS Up to three additional AppServ-HMI to support additional processing areas and clients As many as five EWS As many as eight OWS per PASS or AppServ-HMI Additional application servers for batch management, process information, or asset management if applicable

Distributed

The distributed system is a multi-server, multi-client configuration that supports automating a process with semi-independent areas. The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system. A distributed system can have up to four control areas.

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Chapter 1

EtherNet/IP Control Architecture ExampleEWS PASS

This diagram shows an example of an EtherNet/IP supervisory and control architecture.Domain Controller Application Servers Multiple OWS

Logix5562

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ControlNet Control Architecture ExampleEWS PASS

This diagram shows an example of an EtherNet/IP supervisory and ControlNet control architecture.Domain Controller Application Servers Multiple OWS

EtherNet/IP

Redundant Controllers

ControlNet


11

Chapter 1


Recommended Architecture SizesTable 4 - Architecture System ElementsSystem Element PASS Independent Class

Use these system elements in your process architecture.

Centralized Class One PASS required and includes: FactoryTalk Directory server HMI server Data server Alarms and Events Server 1 EWS required Can have as many as 5 EWS 8 remote clients

Distributed Class One PASS required and includes: FactoryTalk Directory server HMI server Data server Alarms and Events Server (optional)(1) 1 EWS required Can have as many as 5 EWS 8 remote clients for PASS 8 additional remote clients per AppServ-HMI Required 1...6 ControlLogix controllers per PASS 1...6 ControlLogix controllers per AppServ-HMI One AppServ-Batch for each set of six controllers One AppServ-Information Management Three AppServ-HMI

Single computer serves as PASS, EWS, and OWS in an independent workstation

EWS OWS

Included in independent workstation Included in independent workstation

Domain controller Process controller(2)

Required if there are 10 or more Ethernet nodes (IP addresses) 1...5 ControlLogix controllers

Required 1...6 ControlLogix controllers

Application servers

None

One AppServ-Batch One AppServ-Information Management

(1) The PlantPAx system is limited to two FactoryTalk Alarms and Events servers per system, with each supporting up to 10,000 alarms. (2) Controller count based on fully-loaded L63 controllers. Actual controller count allowed may vary based on controller selection and loading. See the next chapter for controller details.

Rockwell Automation offers the Integrated Architecture Builder (IAB) tool that you can use to configure an automation system. It helps you select hardware and generate bills of material for applications that include controllers, I/O, networks, drives, cabling and wiring, motion control, and other devices. IAB also includes a Process System Estimator (PSE) to size your process control hardware. See http://www.rockwellautomation.com/en/e-tools/configuration.html.

12


Chapter

2

Core System Definition

The PlantPAx core system consists of the components required to engineer and maintain a process system. This includes system servers, workstations, and controllers.EWS PASS Domain Controller Application Servers Multiple OWS

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TopicCore Control Hardware I/O Components Redundant Networks Core Servers and Workstations Redundant Servers Skid-based Equipment Engineering Tools

Page14 16 18 20 23 24 25


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Chapter 2


PlantPAx System Release 2.0

The PlantPAx system release 2.0 consists of the following software: RSLogix 5000 software, version 19.x FactoryTalk View software, version 6.0 FactoryTalk Batch software, version 11 FactoryTalk AssetCentre software, version 4.0 FactoryTalk VantagePoint software, version 3.1.5 FactoryTalk Historian software, version 2.2

Core Control Hardware

The core control components are the ControlLogix family of products. The ControlLogix controller functions as the process controller and provides process, sequential, discrete, and drive control. Separate modules provide connectivity to system networks, field devices, and third-party products.

Table 5 - Simplex Controller HardwareHardware Process controller(1) (2) Ethernet interface Product ControlLogix 1756-L61, 1756-L62, or 1756-L63 controller ControlLogix 1756-L72, 1756-L73, 1756-L74, or 1756-L75 controller 1756-EN2TR, 1756-EN3TR, 1783-ETAP (supports device-level ring topology) 1756-EN2T, 1756-ENBT, 1756-EWEB, 1756-EN2F, 1783-ETAP1F, 1783-ETAP2F. The fiber 1783ETAPs support device-level ring topology. 1756-CN2, 1756-CN2R 1756-CNB, 1756-CNBR

ControlNet interface

(1) If environmental conditions warrant, you can use an extreme temperature controller, for example, the 1756-L74XT. (2) For a PlantPAx system, we recommend that you use only the controller platforms characterized in this table. If 1756-L64 or 1756-L65 controllers are used, be aware that the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756-L63 controller (typically 1015%).

Table 6 - Simplex ControlLogix Controller SizingAttribute(1) User memory Total I/O recommended, max Total tags, max Recommended control strategies, max(2) Total control strategies @ 250 ms, max Total control strategies @ 500 ms, max Tags/sec delivered to data server, max(3) 1756-L61 2 MB 375 15,625 60 60 60 10,000 1756-L62 4 MB 750 31,250 125 125 125 10,000 1756-L63 8 MB 1500 62,500 250 125 250 10,000 1756-L72 4 MB 750 31,250 125 125 125 20,000 1756-L73 8 MB 1500 62,500 250 250 250 20,000 1756-L74 16 MB 2250 112,500 450 250 450 20,000 1756-L75 32 MB 2250 112,500 450 250 450 20,000

(1) These values are maximum limits. You may not be able to achieve all of these in a single controller. (2) Representative control strategy (PID loop) includes 1 analog input, 1 analog output, 1 PIDE instruction, 8 logic/math instructions, and 22 alarms with PlantPAx process objects. (3) Assumes RSLinx Enterprise software, version 5.30, at 10 K/s per instance.

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Chapter 2

ControlLogix controllers support redundancy on ControlNet and EtherNet/IP networks. In a redundant controller system on PlantPAx, you need these components: Two 1756 chassis each set up the same with the following: Number of slots Modules in the same slots Redundancy firmware revisions in each module Two additional ControlNet or Ethernet nodes outside the redundant chassis pair One 1756-RM module per chassisTable 7 - Redundant Controller HardwareHardware Process controller(1) Redundancy module Redundant Ethernet network Product ControlLogix 1756-L63 controller, firmware revision 19.x ControlLogix 1756-L73, 1756-L74, or 1756-L75 controller, firmware revision 19.x 1756-RM A redundant Ethernet network is based on architecture topology and requires multiple Ethernet interfaces. 1756-EN2T, 1756-EN2TR A redundant ControlNet network requires a ControlNet interface that support redundant media 1756-CN2R

Redundant ControlNet network

(1) For a PlantPAx system, we recommend that you use only the controller platforms characterized in this table. If 1756-L64 or 1756-L65 controllers are used, be aware that the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756-L63 controller (typically 1015%).

Table 8 - Redundant ControlLogix Controller SizingAttribute(1) User memory Total I/O recommended, max Total tags, max Recommended control strategies, max(2) Total control strategies @ 250 ms, max Total control strategies @ 500 ms, max Tags/sec delivered to data server, max(3) 1756-L63 8 MB 750 31,250 125 60 120 10,000 1756-L73 8 MB 750 31,250 125 120 125 20,000 1756-L74 16 MB 1500 62,500 250 120 220 20,000 1756-L75 32 MB 2250 125,000 450 120 220 20,000



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Chapter 2


I/O Components

I/O components consist of standard I/O modules as well as intelligent and specialty modules. The number of I/O components depends on the number of controllers.

Table 9 - I/O Product Family and Communication InterfaceCategory In-cabinet I/O modules Product 1734 POINT I/O Connectivity 1734-AENT EtherNet/IP adapter 1734-ACNR ControlNet adapter (redundant) 1734-ADN, 1734-ADNX, 1734-PDN DeviceNet adapter Built-in DeviceNet connectivity Built-in DeviceNet connectivity 1794-AENT EtherNet/IP adapter 1794-ACN15, 1794-ACNR15, 1794-ACN15K, 1794-ACNR15K ControlNet adapter 1794-ADN DeviceNet adapter 1797-ACNR15 ControlNet adapter 1794 adapter with 1797-BIC isolator and 1797-CEC connector Built-in EtherNet/IP or DeviceNet connectivity 1738-AENT EtherNet/IP adapter 1738-ACNR ControlNet adapter 1738-ADN12, 1738-ADN18, 1738-ADN18P, 1738-ADNX DeviceNet adapter Built-in DeviceNet connectivity 1756-EN2T, 1756-EN2TR, 1756-EN2F, 1756-ENBT EtherNet/IP module 1756-CN2, 1756-CN2R, 1756-CNB, 1756-CNBR ControlNet module 1756-DNB module Some drives offer built-in EtherNet/IP connectivity; others require separate adapter: 20-COMM-E EtherNet/IP adapter 20-COMM-C, 20-COMM-Q ControlNet adapter 20-COMM-D DeviceNet adapter Built-in DeviceNet connectivity Built-in EtherNet/IP or DeviceNet connectivity Built-in EtherNet/IP connectivity or via 1788-EN2DN linking device Built-in DeviceNet connectivity ControlNet connectivity via 1788-CN2DN linking device Built-in DeviceNet connectivity ControlNet connectivity via 1440-ACNR ControlNet adapter with 1440-DYN02-01RJ module only

1790 CompactBlock LDX I/O 1791D CompactBlock I/O 1794 FLEX I/O

1797 FLEX Ex intrinsically safe I/O On-machine I/O modules 1732 ArmorBlock I/O 1738 ArmorPOINT I/O

1799 Embedded I/O Chassis-based I/O modules 1756 ControlLogix I/O

Variable frequency drives

PowerFlex drives

Soft motor starters Overload relays Motor control centers(1)

150 SMC smart motor controller 193 E1 overload relays 592 E3 overload relays CENTERLINE 2100 CENTERLINE 2500 1440 XM intelligent I/O modules

Condition monitoring

(1) Networked motor control center devices can be used in place of standard I/O modules (digital and analog outputs).

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Chapter 2

Redundant I/OThe 1715 redundant I/O system lets a ControlLogix controller communicate to a remote, redundant I/O chassis over an EtherNet/IP network. The 1715 redundant I/O system provides fault tolerance and redundancy for critical processes by using a redundant adapter pair and multiple I/O modules that have enhanced diagnostics.


Device-level Ring EtherNet/IP Network Redundant I/O Modules

The 1715 I/O system supports as many as 24 I/O modules per set of adapters.Table 10 - 1715 I/O ModulesCat. No. 1715-AENTR 1757-IB16D 1715-OB8DE 1715-IF16 1715-OF8I Description EtherNet/IP adapter 16 point, 24V DC diagnostic input module 8 point, 24V DC diagnostic output module, electronically fused 16 channel, 420 mA, current analog input module 8 channel, 420 mA, current analog output module, isolated


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Chapter 2


Redundant Networks

Consider your topology when weighing redundancy options for EtherNet/IP and ControlNet networks.

EtherNet/IP NetworkEthernet networks have active infrastructures that rely on switches for managing traffic. You can design a network with individual switch devices and devices that have embedded switch technology.Table 11 - Redundant EtherNet/IP TopologiesTopology Redundant Star Recommended for supervisory networks. Description A redundant star topology is essentially where every Layer 2 access switch has dual connections to a Layer 3 distribution switch. Devices are connected to the Layer 2 switches. Advantages Resiliency from multiple connection failures Faster convergence to connection loss Consistent number of hops provide predictable and consistent performance Fewer bottlenecks Disadvantages Additional wiring and ports required Additional configuration complexity

Device-level ring (DLR) Recommended for control and I/O networks.

A DLR network is a single-fault tolerant ring network intended for the interconnection of automation devices. This topology has switches embedded into the end devices themselves; no additional switches are required. The DLR topology does require additional effort to set up and use as compared to a linear network. Advantages Ability to survive a single point of failure or a device being powered down on the ring Simplified cabling Ability to cover long distances with 100 m allowed between each copper segment Very fast network convergence Disadvantages Supervisor-node configuration required Additional configuration complexity Variable number of hops can make performance difficult to predict

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Chapter 2

Table 11 - Redundant EtherNet/IP TopologiesTopology Switch ring(1)

Description A switch ring network is a single-fault tolerant ring network that connects Layer 2 switches to a Layer 3 distribution switch. Advantages Ability to survive a single point of failure or a device being powered down on the ring Simplified cabling Ability to cover long distances with 100 m allowed between each copper segment Disadvantages Additional configuration complexity Longer convergence times Variable number of hops can make performance difficult to predict

(1) Not characterized with PlantPAx system testing, but assumed a valid configuration.

Additional Ethernet features that support high availability include these advanced network resiliency and convergence techniques: EtherChannel and Link Aggregation Control Protocol (LACP) provide additional bandwidth between two devices by aggregating multiple Ethernet connections into a higher bandwidth virtual connection. These protocols quickly recover from the loss of one or more channel members. Flex Links is a Cisco-proprietary resiliency protocol that is for use in redundant star networks. This protocol connects an access switch to a distribution switch.

Redundant ControlNet MediaA ControlNet network supports the option of redundant media.ControlLogix 1756-C2NR ControlNet Node

Redundant Media ControlNet Node

For information on ControlNet media, see ControlNet Media System Components List, AG-PA002.


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Chapter 2


Core Servers and Workstations

The PlantPAx system uses these core servers and workstations: Process automation system server (PASS) HMI application server (AppServ-HMI) Engineering workstation (EWS) Operator workstation (OWS)

Process Automation System Server (PASS)The process automation system server (PASS) is the process system server. The PASS can also provide HMI, data, and OPC server functions. In an independent class architecture, the PASS also serves as the engineering workstation (EWS) and operator workstation (OWS).Table 12 - PASS RequirementsAttribute Computer hardware Product Pentium Core Duo processor or better 1.6 GHz CPU 4 GB memory Dual hard drives (one for application code; one for logging) Dedicated Ethernet card that supports redundant media UPS power backup

Operating system Visualization

Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service) with Service Pack 2, 32-bit FactoryTalk View SE server software FactoryTalk View SE client software FactoryTalk View Studio software(1) FactoryTalk Services Platform server software FactoryTalk Directory software FactoryTalk View Administration Console software RSLinx Enterprise software (includes FactoryTalk Alarms and Events server) RSLinx Classic software (not activated) FactoryTalk Activation server software FactoryTalk Historian interface node

Infrastructure

Additional

Antivirus software OPC interface software

(1) Required only for initial setup. Take advantage of concurrent licensing with an EWS.

Predefined PASS ProductsThese servers are available as prepackaged hardware and software products based on the PlantPAx characterized system elements.Cat. No. 7477-IS2VS100 7477-IS2VS250 Description Process automation system server (PASS) with 100 screens Process automation system server (PASS) with 250 screens

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Chapter 2

HMI Application Server (AppServ-HMI)Add additional HMI application servers as needed based on operational areas in the plant or based on the number of these components: Controllers Alarms, displays, data logs, and historian tags Operator interfacesTable 13 - AppServ-HMI RequirementsAttribute Computer hardware Product Pentium Core Duo processor or better 1.6 GHz CPU 4 GB memory Dual hard drives (one for application code; one for logging) Dedicated Ethernet card that supports redundant media UPS power backup

Operating system Visualization

Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service) with Service Pack 2 FactoryTalk View SE server software FactoryTalk View SE client software FactoryTalk View Studio software FactoryTalk Services Platform server software FactoryTalk View Administration Console software RSLinx Enterprise software (includes FactoryTalk Alarms and Events server) RSLinx Classic software (not activated) FactoryTalk Activation client software FactoryTalk Historian interface node

Infrastructure

Additional

Microsoft Office 200x software Antivirus software OPC interface software

Engineering Workstation (EWS)The engineering workstation (EWS) supports system configuration, application development, and maintenance functions. This is the central location for monitoring and maintaining the systems operation.Table 14 - EWS RequirementsAttribute Computer hardware Product Pentium 4 processor or better 3.0 GHz CPU 3 GB memory ATI video card Dedicated Ethernet card UPS power backup

Operating system Control development

Windows XP Professional operating system Windows 2008 Server operating system (if more than 10 nodes and activation server); 32-bit RSLogix 5000 Professional Edition software (includes Advanced Process Control function blocks) RSLogix Architect software RSLogix Emulate 5000 software


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Chapter 2


Table 14 - EWS RequirementsAttribute Visualization development Batch management, optional(1) Product FactoryTalk View SE client software FactoryTalk View Studio software FactoryTalk Batch Equipment Editor software FactoryTalk Batch Recipe Editor software FactoryTalk Batch View client software FactoryTalk Batch MaterialManager software

Asset management, optional(1) Process information, optional(1)

FactoryTalk AssetCentre client software FactoryTalk AssetCentre audit support FactoryTalk Historian Process Book software FactoryTalk Historian Datalink software FactoryTalk Historian Batch View software FactoryTalk Historian SQC software FactoryTalk VantagePoint development tools IntelliCENTER software for Motor Control Centers FactoryTalk Services Platform software FactoryTalk View Administration Console software RSLinx Enterprise software RSLinx Classic software(2) FactoryTalk Activation server software FactoryTalk Security server software(1) Fuzzy Designer software IntelliCENTER software for motor control centers RSFieldbus software for FOUNDATION Fieldbus devices HIPROM HSNetworxPA software for PROFIBUS PA devices Endress+Hauser Fieldcare software RSNetWorx for ControlNet software

Infrastructure

Optional configuration

Additional

Microsoft Office software Antivirus software

(1) The EWS has the client and configuration tools. You need the associated application server for runtime services. (2) Included with RSLogix 5000 Professional Edition software, version 19.x.

Operator Workstation (OWS)The operator workstation (OWS) provides the graphical view and interface into the process. The workstation is a client of either a PASS or application HMI server. The OWS supports operator interaction and is not meant to support development or maintenance activities.Table 15 - OWS RequirementsAttribute Computer hardware Product Pentium Core Duo processor or better 1.6 GHz CPU 4 GB memory Dual hard drives (one for application code; one for logging) Dedicated Ethernet card that supports redundant media UPS power backup

Operating system Visualization Batch management, optional(1)

Windows XP Professional operating system with Service Pack 3 FactoryTalk View SE client software FactoryTalk Batch client software FactoryTalk Batch eProcedure software

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Chapter 2

Table 15 - OWS RequirementsAttribute Process information, optional Infrastructure Additional(1)

Product FactoryTalk Historian Active View (ProcessBook) client software FactoryTalk Services Platform software FactoryTalk Activation client software Microsoft Office 200x software Antivirus software

(1) The OWS has the client and configuration tools. You need the associated application server for runtime services.

Predefined OWS ProductThis OWS is available as prepackaged hardware and software products based on the PlantPAx characterized system elements.Cat. No. 7477-IC2VC Description Operator workstation (OWS)

Redundant Servers

Based on risk analysis of the probability and impact of a component failure, you may choose to make that component redundant in your architecture. That may include servers, controllers, network, or infrastructure. The PASS and AppServ-HMI servers can be configured as redundant for the following software components: HMI server Alarm server Data serverPrimary Server Secondary Server

For more information about configuration details, see the PlantPAx Process Automation System Reference Manual, publication PROCES-RM001.


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Chapter 2


Skid-based Equipment

The PlantPAx process automation system is a complete, scalable system, from single controller to a fully distributed set of equipment. You can easily integrate skid-based equipment into the overall system. The CompactLogix controller platform offers a solution for skid-based equipment or turn-key system: The application requires the control of multiple loops for temperature, pressure, flow, or level. The application runs as a sub-system with sequencing and automation. The application is controlled as part of the overall process, accepting reference inputs and delivering process variables to an overall programmable controller.

Table 16 - Skid-based Controller SizingAttribute(1) User memory Total I/O recommended, max Total tags, max Recommended control strategies, max(2) Total control strategies @ 250 ms, max Total control strategies @ 500 ms, max Tags/sec delivered to data server, max(3) CompactLogix 1769-L23E 0.5 MB 80 4000 10 10 10 3000 CompactLogix 1769-L35E 1.5 MB 250 12,800 30 30 30 3000


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Chapter 2

Engineering ToolsTable 17 - Engineering ToolsCategory PlantPAx library of process objects

The PlantPAx solution includes additional tools that can be used to develop your process application, in conjunction with the standard Integrated Architecture tools such as RSLogix 5000 software.

Tools Rockwell Automation branded and supported library of building blocks that support process devices (such as valve, motor, and transmitter) consisting of these components: Controller logic (Add-On Instructions) Graphical objects for custom graphics and custom faceplates Historian autodiscovery templates VantagePoint type packages Device integration tools provide access to isolated diagnostics and step-by-step guidance on connectivity, configuration, and commissioning of field devices with the PlantPAx system. These tools include the following: Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller Pre-configured operator faceplates that provide visualization of instruments connected to the network interface Integration documentation that describes the implementation The Logix View utility is an engineering tool that helps you bulk-generate portions of your application based on libraries of logic and human interface components: Create logic templates from your control logic libraries and define how to map tags when creating instances. Create display templates from your visualization libraries and define how to map tags when creating instances. Contact your local office for this utility.

PlantPAx preferred integration tools

Application development

Access engineering tools and associated documents from the Rockwell Automation Knowledgebase at http://www.rockwellautomation.com/ knowledgebase/. See Knowledgebase Answer ID 62366 for the PlantPAx table of contents. Some downloads may require a TechConnectSM contract.


25

Chapter 2


Notes:

26


Chapter

3

Field Device Integration and Asset ManagementField device components connect process instrumentation and electrical (power) products. Field device components can communicate through the EtherNet/IP, DeviceNet, ControlNet, HART, FOUNDATION Fieldbus, and PROFIBUS PA networks.

EtherNet/IP FOUNDATION Fieldbus EtherNet/IP ControlNet

HART FOUNDATION Fieldbus

PROFIBUS PA

TopicEtherNet/IP Devices ControlNet Devices DeviceNet Devices HART Devices FOUNDATION Fieldbus Devices PROFIBUS PA Devices Asset Management

Page28 29 30 31 32 33 34


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Chapter 3

Field Device Integration and Asset Management

EtherNet/IP Devices

The EtherNet/IP network protocol is an open, industrial-networking standard that supports both real-time I/O messaging and message exchange. The EtherNet/IP network uses off-the-shelf Ethernet products and physical media.

EtherNet/IP NetworkLogix5562


ETHERNETST FLT

ANALOG INPUT0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 O 8 9 10 1112131415 K 8 9 10 1112131415 ST FLT ST FLT

ANALOG INPUT0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 O 8 9 10 1112131415 K 8 9 10 1112131415

AC INTPUTST 0 1 2 3 4 5 6 7 O ST 8 9 10 1112131415 K

POWER

RUN

FORCE BAT

ST FLT

FOUNDATION Fieldbus Network

RUN

REM

PROG

RXD

TXD

OK

RXD

TXD

OK

DIAGNOSTIC

DIAGNOSTIC

DIAGNOSTIC

B

A

B

A

HART Devices

Motor Control Center

Logix5562

ETHERNETI/O RS232 OKST FLT

ANALOG INPUT0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 O 8 9 10 1112131415 K 8 9 10 1112131415

AC INTPUTST 0 1 2 3 4 5 6 7 O ST 8 9 10 1112131415 K

POWER

RUN

FORCE BAT

ST FLT









RUN

REM

PROG

RXD

TXD

OK

DIAGNOSTIC

DIAGNOSTIC

DeviceBus Status


120 VAC Input

220 VAC Input

24VDC Sink Input

24VDC Source Output

120V 220 VAC Output

220VAC Input

0

4

0

0

0

4 0

4

0

0

12 31734 OW4

5 6 7

1 2 31734 IA4

1 2 31734 IM4

1 2 31734 IB8

5 1 6 2 7 31734 OB8E

5 6 7

1 2 31734 OA4

1 2 31734 IM4

B

A

PROFIBUS PA Network

In a PlantPAx system, the EtherNet/IP network provides the communication backbone for the supervisory network for the workstations, servers, and the controllers. The EtherNet/IP network also supports controller downlinks and connections to remote I/O and field device interfaces. EtherNet/IP is supported by the Open Device Vendors Association (ODVA).Table 18 - EtherNet/IP InterfaceCategory ControlLogix controller interface Product 1756-EN2T, 1756-EN2TR,1756-EN2F 1756-ENBT 1756-EWEB 1757-FFLD2 1757-FFLD4 1788HP-EN2PA-R(1) Description ControlLogix EtherNet/IP scanner.

EtherNet/IP to FOUNDATION Fieldbus linking device. Supports two or four H1 FOUNDATION Fieldbus networks. HIPROM Technologies, EtherNet/IP to PROFIBUS PA linking device. Supports redundant PA media and DLR capable Ethernet.

(1) Can be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.

Some field devices support a direct connection to EtherNet/IP networks. For example: Endress+Hauser, Promass 80 and Promass 83 Coriolis flowmeters for liquid and gas flows Endress+Hauser, Promag 53 electromagnetic flowmeter for conductive liquids

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Chapter 3

Many I/O and field device products are available via the Encompass third-party product referencing program. To sort and filter products from best-in-industry suppliers in your region, see http://www.rockwellautomation.com/encompass.

ControlNet Devices

The ControlNet network is an open, control network for real-time, high-throughput applications that uses the Common Industrial Protocol (CIP) to combine the functionality of an I/O network and a peer-to-peer network, providing high-speed performance for both functions. ControlNet is supported by the Open Device Vendors Association (ODVA).EtherNet/IP Network


ControlNet Network

FOUNDATION Fieldbus Network

HART Devices

PROFIBUS PA Network

In a PlantPAx system, the ControlNet network supports controller downlinks and connections to remote I/O and field device interfaces.Table 19 - ControlNet InterfaceCategory ControlLogix controller interface Product 1756-CN2, 1756-CN2R 1756-CNB, 1756-CNBR 1757-FFLDC2 1757-FFLDC4 1788HP-CN2PA-R(1) Description ControlLogix ControlNet scanner. ControlNet to FOUNDATION Fieldbus linking device. Supports two or four H1 networks. Compatible with ControlLogix redundancy and redundant ControlNet media. HIPROM Technologies, ControlNet to PROFIBUS PA linking device. Supports redundant PA media and redundant ControlNet media.

(1) Can be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.


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Chapter 3


DeviceNet Devices

The DeviceNet network is an open, device-level network that provides connections between simple industrial devices (such as sensors and actuators) and higher-level devices (such as PLC controllers and computers). The DeviceNet network uses the proven Common Industrial Protocol (CIP) to provide the control, configuration, and data collection capabilities for industrial devices. DeviceNet is supported by the Open Device Vendors Association (ODVA).

DeviceNet Network

PowerFlex Drives

CENTERLINE Motor Control Center

In a PlantPAx system, the DeviceNet network connects networked control devices.Table 20 - DeviceNet InterfaceCategory ControlLogix controller interface Product 1756-DNB Description ControlLogix DeviceNet scanner

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Chapter 3

HART Devices

HART is an open protocol designed to connect analog devices.

Controller Network

HART Devices

The PlantPAx system interfaces both directly and via remote I/O modules to provide a single termination point to gather analog process variables and the additional HART digital data.Table 21 - HART InterfaceCategory Chassis-based I/O modules Product 1756-IF8H, 1756-OF8H 1756-IF16H MVI56-HART Description ControlLogix analog I/O modules with the following: Standard profiles in RSLogix 5000 software DTMs ProSoft Technology, HART multi-drop communication interface module for ControlLogix system for use in FactoryTalk AssetCentre Process Device Configuration or other asset management system based on FDT Technology (IEC-62453, ISA103). Spectrum Controls, analog input module with HART for the POINT I/O system. Spectrum Controls, analog, isolated input and output modules with HART for Compact I/O. FLEX analog I/O and FLEX Ex analog I/O modules with the following: Standard profiles in RSLogix 5000 software DTMs Spectrum Controls, HART I/O with an EtherNet/IP interface. See the Encompass website for Spectrum product offerings. Pepperl+Fuchs, wireless HART adapter. See the Encompass website for Pepperl+Fuchs product offerings. Endress+Hauser, handheld configuration and diagnostic device. See the Encompass website for Endress+Hauser product offerings.

Distributed I/O modules

1734-sc-IF4H 1769-sc-IF4IH, 1769-sc-OF4IH 1794-IE8H, 1794-OE8H 1794-IF8IH, 1794-OF8IH 1797-IE8H, 1797-OE8H

Multiplexers/gateways

EtherNet/IP interface Wireless HART adapter

Network configuration

Handheld device

HART device integration tools include the following: Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller Pre-configured operator faceplates that provide visualization of instruments connected to the network interface Integration documentation that describes the implementation, at http://www.rockwellautomation.com/solutions/process/integrationdocs. html For information about using Add-On Instructions and faceplates with HART data in a FactoryTalk View SE application, see the Rockwell Automation Knowledgebase Answer ID 54847 at http://rockwellautomation.custhelp.com.


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Chapter 3


FOUNDATION Fieldbus Devices

The FOUNDATION Fieldbus network is a protocol designed for robust, distributed control of process control applications. Devices connected by a FOUNDATION Fieldbus network can be used for sophisticated, highly-distributed process control.

EtherNet/IP Network

ControlNet Network 1757-FFLDC2 or 1757-FFLDC4

1757-FFLD4 H1 (1)

H1 (2) H1 (3) H1 (4)

PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNet/IP and ControlNet linking devices.Table 22 - FOUNDATION Fieldbus InterfaceCategory EtherNet/IP interface ControlNet interface Product 1757-FFLD2 1757-FFLD4 1757-FFLDC2 1757-FFLDC4 Power conditioning Terminators Segment protection Configuration software 9308 series RSFieldbus software Description Bridge from an Ethernet network to either two or four H1 networks. Bridge from a ControlNet network to either two or four H1 networks; compatible with ControlLogix redundancy and redundant ControlNet media. Pepperl+Fuchs, FOUNDATION Fieldbus components, such as valve couplers, surge protectors, terminators, distributors, and power products. See the Encompass website for Pepperl+Fuchs product offerings. Configure FOUNDATION Fieldbus devices.

FOUNDATION Fieldbus network components

FOUNDATION Fieldbus device integration tools include the following: Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller Pre-configured operator faceplates that provide visualization of instruments connected to the network interface Integration documentation that describes the implementation, at http://www.rockwellautomation.com/solutions/process/integrationdocs. html

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Chapter 3

PROFIBUS PA Devices

The PROFIBUS PA network is the PROFIBUS solution for process automation. The PROFIBUS PA network connects automation systems and process control systems with field devices such as flow, level, pressure, and temperature transmitters.EtherNet/IP Device Level Ring EtherNet/IP

EtherNet/IP Linear

Redundant ControlNet PROFIBUS PA Linking Devices

PROFIBUS PA Linking Devices

PROFIBUS PA Devices PROFIBUS PA Devices PROFIBUS PA Devices

Table 23 - PROFIBUS PA InterfaceCategory PROFIBUS interface Product 1788HP-EN2PA-R(1) Description HIPROM Technologies, EtherNet/IP to PROFIBUS PA linking device. Supports redundant PA media and DLR capable Ethernet. Linking device includes power conditioning. HIPROM Technologies, ControlNet to PROFIBUS PA linking device. Supports redundant PA media and redundant ControlNet media. Linking device includes power conditioning. HIPROM Technologies, linking devices have built-in power conditioning. HIPROM Technologies, intelligent junction box PAR-JB (4 junctions) and PAR-JB6 (6 junctions) support redundancy and do not require separate power supplies. Pepperl+Fuchs, PROFIBUS components, such as valve couplers, surge protectors, terminators, distributors, and power products. See the Encompass website for Pepperl+Fuchs product offerings.

1788HP-CN2PA-R(1)

PROFIBUS network components

Power conditioning Junction boxes

PROFIBUS network components

Power conditioning Terminators Segment protection

(1) Must be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.

PROFIBUS PA device integration tools include the following: Pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and ControlLogix controller Pre-configured operator faceplates that provide visualization of instruments connected to the network interface Integration documentation that describes the implementation, at http://www.rockwellautomation.com/solutions/process/integrationdocs. html


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Chapter 3


Asset Management

Asset management is an extension to the PlantPAx system that adds maintenance and plant operations to the core components. This includes comprehensive diagnostics, calibration, real-time monitoring, as well as auditing equipment and network health to improve overall resource availability.

Asset Management ServerThe asset management server provides a centralized system management for end field devices.Table 24 - Asset Management Server RequirementsAttribute Computer hardware Product Pentium 4 processor or better 3.0 GHz CPU 2 GB memory Dedicated Ethernet card UPS power backup

Operating system Asset management software

Windows 2003 Server operating system FactoryTalk AssetCentre server software FactoryTalk AssetCentre assets (5, 25, 100, 500, 1000, or 5000) FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software Microsoft SQL Server 2000 software

Optional software

IntelliCENTER software for motor control centers

Calibration ProductsThese calibration tools are available to manage calibration requirements, specifications, schedules, calibration results, and reports.Table 25 - Calibration ProductsProduct Process device configuration tool Calibration management tool Description 9515-ASTPRDCFENE FactoryTalk AssetCentre Process Device Configuration software 9515-ASTCLMANENE FactoryTalk AssetCentre Calibration Management software 9515-ASTCLWRKENE FactoryTalk AssetCentre Calibration Management remote workstation 9515-ASTCLFLKENE FactoryTalk AssetCentre Calibration Management FLUKE interface 9515-ASTCLDRKENE FactoryTalk AssetCentre Calibration Management Druck interface 9515-ASTCLTMNENE FactoryTalk AssetCentre Calibration Management Trnsmtn interface

Loop 705, 707, 707Ex, 715 Multifunction 725, 741, 743B, 744 Pressure 717, 718, 718Ex, 719 Temperature 712, 714, 724

Fluke handheld process-loop calibrators for the calibration and troubleshooting of 4...20 mA process control loops Fluke handheld, multifunction calibrators for temperature, pressure, voltage, and mA parameters Fluke pressure calibrators measure pressure to 0.05%, DC mA. The 718 and 718Ex have an onboard pump. Ranges: 30 and 100 PSIG Fluke temperature calibrators include the following: 712: RTD source/measure 714: thermocouple (T/C) source/measure 724: source/measure RTD, T/C, measure mA, 24V loop

34


Chapter

4

Batch Management and Control

PlantPAx batch management and control solutions offer flexible production, equipment-independent recipe management, batch-independent equipment control, and regulatory compliance. The scalable integrated solutions leverage industry standards to meet small, basic batch and sequencing needs, as well as distributed, comprehensive batch and sequencing needs. System size varies from small to large and system requirements vary from simple to complex. Not all basic systems are small or have simple requirements, and not all comprehensive system are large or complex. Small systems can have complex requirements or vice versa.

TopicBasic Batch and Sequencing Comprehensive Batch and Sequencing

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Basic solutions provide capabilities for small or simple systems to use core system functions, including Logix5000 controllers and FactoryTalk View HMI. Generally these solutions do not need the functionality provided by server-based FactoryTalk Batch software solutions. Comprehensive solutions provide capability for large or complex systems to use modular software components. This includes FactoryTalk Batch software, eProcedure software, Material Manager software, integrated visualization, batch reporting services, and integrated security and audit services. Each solution can migrate to the next. These four solutions overlap because each individual solution can solve many of the same core requirements. All solutions support PhaseManager software and the PlantPAx Process Library.Table 26 - Select a Batch SolutionBatch Application Function Custom coded solution (changes to recipe require code change) Leverage PhaseManager and SFC programming (based on built-in controller-firmware functionality) Standard controller/HMI application solution without the need for a separate server (no server or additional software required, limited by controller memory) Single unit execution (product made in single unit) Recipe management (configurable and flexible formula, procedure, and equipment) Data collection, reporting, and analysis (requires sever for long term storage and analysis) Equipment allocation and arbitration (shared resources and/or shared resources) Complex recipes (product recipes with loops, branches, and transitions; phases with more than four inputs and four outputs) Multiple unit coordination (product is made across multiple, coordinated units) More than 32 recipes String values or numeration required for parameter and report values Number of parameters or report values required by phase > 4 Require class-based recipes Basic Coded X X X X X X X Basic Configured Comprehensive In-Chassis Server Comprehensive Application Server

X X

X X

X X

X X X

X X X

X X X X X

X X X X X

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Table 26 - Select a Batch SolutionBatch Application Function Large system with complex routing (more than five units; may use complex routing algorithms) Manual and electronic work instructions (web-based instructions, embedded pictures, video) Material management (material container, lot, location, and property tracking) Basic Coded Basic Configured Comprehensive In-Chassis Server Comprehensive Application Server X

X X

Basic Batch and Sequencing

Basic batch and sequencing options are controller-based solutions that rely on programming to manage the application.

Basic Coded (custom)Basic Coded Custom Code

Coded solutions generally target systems where procedural flexibility is not the primary concern. This solution requires changes to the controller program to change the recipe or sequence. Formula flexibility can be added through use of tools such as Recipe Pro/Plus or custom code. In these systems, the procedure is fixed, but parameters can be flexible. Generally these solutions are optimized for fixed sequences, fixed formulation, and simple equipment control local to the process.

Basic ConfiguredBasic Configured Logix Batch & Sequence Manager

Basic Coded Custom Code

Configured solutions generally address requirements for higher level of flexibility. This includes both procedural (sequence) and formula (setpoint). These generally are focused on independent, stand alone units (mixers, blenders, reactors). However, these systems do not require a server and software such as FactoryTalk Batch software for execution. This solution leverages the Logix Batch and Sequence Manager application. The Logix Batch and Sequence Manager application leverages the Logix5000 platform for control code and FactoryTalk View software for visualization. This application is freely available as part of PlantPAx tools and applications. The application enables local, single unit supervision and control, but supports multiple, independent units in a single controller.


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The Logix Batch and Sequence Manager application does the following: Offers configurable equipment definitions (phases, parameters, report registers) and flexible recipe management (master/control recipe definition) with HMI secured edits Leverages standard ISA-88 models for control (state model, recipe model) Offers connection to equipment through a bit interface or standard PhaseManager interface Supports ControlLogix controller redundancy Features an intuitive runtime interface (If you choose FactoryTalk View ME software on a PanelView Plus terminal, there is a limitation of a 12-inch or larger screen and 600 x 800 resolution or greater) For the Logix Batch and Sequencing Manager application, see the Rockwell Knowledgebase Answer ID 62366 at http://rockwellautomation.custhelp.com.

Comprehensive Batch and Sequencing

Comprehensive batch and sequencing solutions leverage core Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software). PhaseManager software continues to be the basis for process control code in the controller. FactoryTalk Batch software provides recipe management, information management, process management, and unit supervision. The comprehensive batch and sequencing options run on a server to manage the application. The server can be an in-chassis module or an application server.

Comprehensive Chassis-based Server Basic Configured Logix Batch & Sequence Manager Basic Coded Custom Code

In-chassis ServerThe in-chassis batch server is the Logix 56SAM-838 specialty module for a ControlLogix system from Online Development, Inc. This solution is a local, in-chassis option for running FactoryTalk Batch software. It eliminates the need for additional server infrastructure and keeps batch control local to the process. Target sizing for this module is less than five units.

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Comprehensive Application Server Comprehensive Chassis-based Server Basic Configured Batch & Sequence Manager Basic Coded Custom Code

Application ServerThe application server is the traditional FactoryTalk Batch solution. This solution offers comprehensive batch management capability on a standard application server. Traditional batch software and server solutions are required for large or complex systems.

Table 27 - Batch Server RequirementsAttribute Application server Requirements, min Pentium 4 processor or better 3.0 GHz CPU 2 GB memory Dedicated Ethernet card UPS power backup recommended

Operating system Batch

Batch version 11 supports Windows 2008 Server operating system, 32-bit Batch version 10 supports Windows 2003 Server operating system, 32-bit FactoryTalk Batch server software FactoryTalk Batch Equipment Editor software FactoryTalk Batch Recipe Editor software FactoryTalk Batch Client software FactoryTalk Batch Archiver software

Infrastructure

FactoryTalk Services Platform client RSLinx Classic software FactoryTalk Activation client software FactoryTalk Historian software Batch Event Interface software Batch System Status tool

Additional


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Additional CapabilitiesTo complement the batch server, consider adding these additional capabilities to your PlantPAx system.Table 28 - Additional Batch CapabilitiesServer FactoryTalk eProcedure software Description Provides process management for manual operations: Provides automated operator instructions for manual processes Integrates manual instructions into automatic batch recipe execution These are typical procedures that can be automated: Manual batch execution and prompts Complex standard operating procedures Portable hand held applications Product changeover and packaging line changes Equipment startup and shutdown sequences Abnormal condition handling Cleaning and maintenance procedures Provides material management for batch manufacturing: Provides an active material management and inventory system Enables material-based phase definitions in batch execution Enables just-in-time material and equipment selection for flexible batch manufacturing and production scheduling These are typical uses of the material management server: Use as a standalone material management and inventory system Provide interfaces for integrating in-house material inventory systems with plant production processes Integrate with material identification systems, such as barcode readers Enable material-based phases if storage locations are flexible

FactoryTalk Batch Material Manager software

Additional ToolsPlantPAx Batch tools and applications are available on the Rockwell Automation Knowledgebase. For the specific PlantPAx Table of Contents, see Knowledgebase Answer ID 62366 at http://rockwellautomation.custhelp.com. These are the available batch tools.Table 29 - Batch ToolsTool Integrated visualization (integrated visualization screens are added to the PASS) Description Offers configurable, pre-engineered FactoryTalk View graphics with embedded FactoryTalk Batch components. See Knowledgebase Answer ID 62372: Full-screen graphics Pop-up graphics Documented batch API code examples Integrates batch status information into the operator view. See Knowledgebase Answer ID 67642.

Batch system status (installed on the AppServ-Batch and graphics are added to the PASS) Batch reporting (requires AppServ-Batch and AppServ-Information Management)

Pre-configured, web-based batch reports. Deploy and run these reports through a standard web browser or integrated VantagePoint portal. Create custom batch reports from existing templates. See Knowledgebase Answer ID 62367. The reports include the following: Batch reports: batch listing, batch summary, batch detail Material reports: material usage, forward tracking, backward tracking Analysis reports: batch execution, duration comparison, batch exceptions

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Batch High Availability OptionsBatch high availability options depend on the hardware and software options in the system: For the application server, leverage standard hardware options for redundant power supplies, drives, and dual Ethernet cards for redundant batch servers. With either the in-chassis or application server, standard FactoryTalk Batch software supports a warm back-up option. The primary server copies real-time data to the back-up server. On failure, the process goes to a controlled state. On restart of the back-up server, you clear the failure and the process resumes where it left off. For the application server in a system where a bump in the process cannot be tolerated, FactoryTalk Batch software supports a real-time, uninterrupted high availability option that leverages Marathon technology or VMWare virtualization. A redundant ControlLogix system with PhaseManager software provides protection so that the control platform continues to execute during a hardware failure.

Marathon Technology or VMWare Virtualization in Single Server

Redundant Servers with: - Standard, Redundant Hardware Options and/or - FactoryTalk Batch Warm Backup

Ethernet

ControlNet

Redundant Controllers with a PhaseManager Application


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Notes:

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5

Process Information

PlantPAx process information relies on decision-making tools and dashboards to provide both real-time and historical access to and analysis of process information throughout the enterprise. There are two key areas of focus.Table 30 - Strategic Product ManagementProcess Information Focus Data management Features A distributed, data management strategy enables different focuses of data by various users: Operator viewing data from the machine directly in the HMI Supervisor viewing data to make plant-wide decisions Manager viewing key KPIs from each plant and evaluating plant performance

Decision support

A decision support strategy addresses the need to rapidly capture and evaluate information to make business decisions. This starts by efficiently and reliably collecting data and integrates the support tools necessary to analyze, view, and summarize that data. Portals and dashboards are key to presenting users the information they need, when they need it.

PlantPAx process information provides the right data at the right place at the right time.TopicData Management Decision Support Information Management Server

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Process Information

Data Management

A data management strategy provides the following: Distributed data collection to effectively collect and verify contextual process data Storage management to provide reliable and efficient data storage with easy access A data management strategy, considers overall system data: Distributed historian collection and storage options FactoryTalk Alarms and Events data FactoryTalk Batch event data A distributed historical-data management strategy offers localized, chassis-based, high-speed data collection and recording, as well as site and enterprise solutions.

Table 31 - Distributed Historical Data Management OptionsType of Data Time series Requirements High-speed, on machine data collection < 2500 tags Option Embedded server module for ControlLogix chassis comes with FactoryTalk Historian Machine Edition software already installed: 1756-HIST1 (1 GB) server module 1756-HIST2 (2 GB) server module Continuous data buffer is compatible with FactoryTalk Historian SE software, which allows the module to offload and forward that data FactoryTalk Historian Site Edition software is a scalable process historian that provides real-time access to reliable information: Provides data capture, management, and analytical capabilities to support decision-making. Auto Discovery and Auto Configuration features reduce deployment time and lower total cost of ownership FactoryTalk Historian Enterprise Edition software is a multi-layer data collection historian supports strategies where data historians are required at any level from Line, Plant, Site, and all the way to Enterprise deployments, such as regions, divisions, and other sub entities of a large enterprise. Leverages the scalability and performance in the OSIsoft PI technology. Select a Microsoft SQL server database to act as the central collection point for event based data: FactoryTalk Alarms and Events data FactoryTalk Batch data

Longer term data storage > 2500 tags

Aggregate data from multiple servers Collect and store millions of data streams for plant data across the enterprise Support a central view of data

Event based

Relational database

FactoryTalk Historian supports a complete redundant and highly available system architecture. Redundancy means no loss of data. Redundant interface nodes provide data integrity. Each interface node consumes data points so the total number of tags used must be doubled. High availability means that you do not lose visibility to the collected data. In order to accomplish this, you need redundant servers. Install several historian servers in a Historian Collective and install two redundant interface nodes for the collective per data source.

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