PlantPAx Process Automation System · Publication PROCES-SG001B-EN-P - September 2009 7 PlantPAx Process Automation System Overview Chapter 1 Process System Elements A process control

PlantPAx Process Automation System

Selection Guide

Important User InformationSolid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls (publication SGI-11 available from your local Rockwell Automation sales office or online at httpwwwrockwellautomationcomliterature) describes some important differences between solid state equipment and hard-wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable

In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment

The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams

No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual

Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited

Throughout this manual when necessary we use notes to make you aware of safety considerations

Allen-Bradley Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc

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

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

ATTENTIONIdentifies 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 HAZARDLabels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present

BURN HAZARDLabels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures

3Publication PROCES-SG001B-EN-P - September 2009 3

Table of Contents

Chapter 1PlantPAx Process Automation System Overview

Introduction 5Architecture Classes 9Independent Class Architecture Example 10Centralized Class Architecture Example 12Distributed Class Architecture Example 14Recommended Architecture Sizes 16

Chapter 2PlantPAx Core System Introduction 17

Core Control Hardware 18Core Servers and Workstations 19Engineering Tools 23

Chapter 3PlantPAx Field Device Integration and Asset Management

Introduction 25EtherNetIP Devices 26ControlNet Devices 27DeviceNet Devices 28HART Devices 30FOUNDATION Fieldbus Devices 31PROFIBUS PA Devices 33Asset Management 35

Chapter 4PlantPAx Batch Management and Control

Introduction 37Basic Batch and Sequencing 39Comprehensive Batch and Sequencing 41Material Management 44

Chapter 5PlantPAx Process Information Introduction 47

Information Management 48

Chapter 6PlantPAx Plantwide Optimization Introduction 51

Chapter 7PlantPAx Critical Process Control and Safety Systems

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

4 Publication PROCES-SG001B-EN-P - September 2009

Table of Contents

Chapter 8PlantPAx Infrastructure Introduction 61

Domain Controller 61Ethernet Hardware 62System Software and Services 63

Chapter 9PlantPAx Migration Tools Introduction 65

Migration Tools 66

Chapter 1

PlantPAx Process Automation System Overview

Introduction The PlantPAx system represents the Rockwell Automation culmination of significant investment in automation technology in the process industry The PlantPAx system unifies core Integrated Architecture process automation capabilities and technologies with those of market leading partners such as OSIsoft Endress+Hauser and acquisitions like Incuity Pavilion Technologies ICS Triplex XirsquoAn Hengsheng and ProsCon under a common systems and solutions umbrella to provide a scalable open and cost-effective process solution

Chapter 1 PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas

PlantPAx System Focus Areas

Focus Area Description

Core system The PlantPAx core system consists ofbull engineering development environment

bull system-wide visualization

bull multi-disciplined process control

Size the core for small single-unit systems or add to the core for large highly-distributed multi-area applications Based on Integrated Architecture automation products the core system can be extended by adding capabilities such as batch management and control information management or asset management while maintaining the capability to meet critical process control availability and safety requirements

Field device integration and asset management

In addition to supporting the most extensive range of IO products in the industry the core system provides integration with

bull field devices such as HART FOUNDATION Fieldbus and PROFIBUS PA devices for process instrumentation

bull DeviceNet ControlNet 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 code management vibration monitoring and device management

Batch management and control The PlantPAx system enables flexible production equipment-independent recipe management batch-independent equipment control and support for regulatory compliance These solutions are scalable and leverage industry standards to meet small basic batch and sequencing needs as well as distributed comprehensive batch and sequencing needs

Process information An integrated set of decision-making tools and dashboards provide real-time access to and analysis of process and production information throughout the enterprise

bull Produce web-based KPI dashboards and reports

bull Deliver timely information to appropriate personnel throughout manufacturingmdashderived from various manufacturing processes

A distributed historical data management strategy offers localized chassis-based high-speed data collection and recording as well as site and enterprise solutions to meet the most demanding requirements

Critical process control and safety systems

The PlantPAx system supports scalable solutions that meet specific requirements for availability and safety

bull 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 for predictive control environmental performance management and production performance management

Infrastructure Infrastructure components are built on open industry standards support the entire PlantPAx system and provide connectivity to higher level business systems

Publication PROCES-SG001B-EN-P - September 2009 7

PlantPAx Process Automation System Overview Chapter 1

Process System Elements

A process control system can be defined with system elements (combinations of hardware and software products)

The number of controllers in a control area depends on the controller loadingbull Each controller supports a specified number of field device interfacesbull Each controller has the capacity for a specific number of control

strategies which can be estimated based on the type of IO connected to a controller

The number of servers depends on the number ofbull controllersbull alarms displays data logs and historian tagsbull operator interfaces

System Element Description

Process automation system server (PASS) The PASS is a required system element that provides central name resolution and look up services The PASS also hosts a FactoryTalk View HMI server and an RSLinx Enterprise data server

Operator workstation (OWS) The OWS provides an interactive graphical interface to monitor and control the process

Engineering workstation (EWS) The EWS provides a single development platform for creating and maintaining control strategies and for configuring system elements The EWS is also a central storage location for configuration management

Application server (AppServ) Application servers provide additional system capacity such asbull additional HMI servers for additional visualization requirements

bull batch management for the system-wide batch management and control

bull information systems for the collection of system process databull asset management code management and field device configuration

Controller The process controller is a multitasking multidiscipline controller that supports continuous batch discrete and motion applications Different control strategies are segmented to execute at appropriate rates

The ControlLogix controller supports continuous process applications including Advanced Process Control functions with its deterministic time-based execution mode The controller supports high-speed controller and motion operations by using a continuous scan mode and supports event-driven operations using event-based control

Maintenance workstation (MWS) The MWS typically a laptop provides similar functionality as the EWS and is designed to be portable so it can be used locally to monitor and debug system problems in the field

Independent workstation (IndWS) In an independent class architecture the independent workstation (IndWS) combines the rolls of the PASS OWS and EWS all in one computer

Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities

Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements

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 Clients

Multiple Servers Multiple Clients

Independent Class Architecture Example

The independent class architecture supports simpler process control configurations The independent class architecture supports process control and batch functions The independent class architecture has limited supervisory functions because it uses only one workstation (the independent workstation) onto which all the software is loaded You can expand the independent system to include site manufacturing operations as needed

An independent class architecture consists of these system elements bull One independent workstation This single personal computer combines

software to provide ndash PASS functionality as the process system serverndash EWS functionality to configure and maintain the systemndash OWS functionality for the interactive graphical interface by using

custom graphics faceplates alarms data logging and trendsbull Typically five process controllers with 125 complex regulatory-control

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

bull 64 IO modules on an unscheduled remote IO ControlNet networkbull IO components that are any IO type and nominally 1024 points per

controller (2048 points if hybrid system with higher discrete control) 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)bull Networked motor control center devices can be used in place of

standard IO modules (digital and analog outputs) A networked MCC supports as many as 45 devices typicallyndash 10 variable frequency drives (count as analog devices)ndash 35 motor starters (count as digital devices)

bull Optional MWS as a laptop

This diagram shows an example independent class architecture

Centralized Class Architecture Example

Add workstations to expand the independent class architecture to a centralized class architecture that supports

bull multiple OWS through out the production area a centralized EWS for system-wide development and optional application servers for functions such as batch and asset management

bull additional controllers in the systembull optional reporting information management data collection and

process optimizationThe 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

bull one dedicated PASS as the central HMI serverbull one dedicated EWS for the development and maintenance of the full

system including system securitybull multiple OWS for the interactive graphical interfacebull application servers for batch management data acquisition (historian)

or change management (asset management)bull multiple MWS typically laptops for system maintenance

A centralized system supports these system elementsbull One PASSbull As many as eight OWSbull Typically five process controllers with 125 complex regulatory-control

bull 64 IO modules nominally on an unscheduled remote IO ControlNet network

bull IO components that are any IO type and nominally 1024 points per controller (2048 points if hybrid system with higher discrete control) 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

bull Multiple MWS as laptops

This diagram shows an example centralized class architecture

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 flexibility of the distributed system lets you implement large distributed systems across a plant mill or manufacturing facility and consistently integrate all control facets under a single architecture

The distributed system is a multi-server multi-client configuration that supports automating a process with semi-independent areas The distributed system supports

bull dedicated PASSbull dedicated EWS for the development and maintenance of the full system

including system securitybull multiple OWS for the interactive graphical interfacebull multiple application servers for batch management information

management or change management (asset management)bull multiple distributed HMI application serversbull multiple MWS typically laptops for system maintenance

Use a distributed system for applications that require independent but connected control areas Typical distributed systems include independently operated production lines A distributed system can have up to four control areas Each of the four control areas supports these elements

bull One PASSbull As many as eight OWSbull One central EWSbull Typically 5 process controllers with 125 complex regulatory-control

bull 64 IO modules nominally on a unscheduled remote IO ControlNet network

This diagram shows an example distributed class architecture

Recommended Architecture Sizes

Use these system elements in your process architecture

System Element Independent Class Centralized Class Distributed Class

Independent workstation

Independent workstation (single computer) functions as

bull PASS

bull EWS

bull OWS

None None

EWS Included in independent workstation

bull 1 EWS required

bull Can have as many as 5 EWS

bull 1 EWS required

PASS Included in independent workstationHMI supports these on scan

bull 1000 active 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

bull HMI server

bull Data server

Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with

bull 1000 display points per OWS

OWS Included in independent workstation

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

Domain controller Required if there are 10 or more Ethernet nodes (IP addresses)

Required Required

Process controller 15 ControlLogix controllersbull 125 control strategies

(loops) per controller at a 250 ms period

bull 375 total control strategies per system

16 ControlLogix controllersbull 125 control strategies

16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI

bull 125 control strategies (loops) per controller at a 250 ms period

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

COMM STATUS

Channel A

Channel B

REDUNDANTCOAX BARRIER

Operator Workstation(OWS)

Process Automation System Server

(PASS)Domain Controller

Engineering Workstation

System Printers

ControlNet Network

Redundant Controllers

Local Operator Workstation

EtherNetIP Network

Remote IO Racks

FOUNDATION Fieldbus Network

Intrinsically Safe Area

HART IO

XM Condition Monitoring

CENTERLINEMotor Control Center

Topic Page

Core Control Hardware 18

Core Servers and Workstations 19

Engineering Tools 23

Chapter 2 PlantPAx Core System

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

Additional Resources

Control Hardware

Hardware Product

Process controller ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant controller

bull Firmware revision 168 redundant controller

IO modules 1756 discrete analog and specialty

Redundancy modules bull 1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)(1)

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

Display devices bull 1700 integrated display computer

(1) PhaseManager and FactoryTalk Alarms and Events applications require this enhanced redundancy solution

Resource Description

ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components

NetLinx Selection Guide publication NETS-SG001 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

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)

Process Automation System Server (PASS)

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

Computer Requirements - PASS

Attribute Requirement

Computer hardware bull Pentium 4 processor or better

bull 30 GHz CPU

bull 2 GB memory

bull Dual hard drives (one for application code one for logging)

bull Dedicated Ethernet card that supports redundant media

bull UPS power backup

Software - PASS

Software Product

Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)

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 RSLinx Enterprise software (includes FactoryTalk Alarms and Events server)

bull RSLinx Classic software (not activated)

bull Logix5000 Clock Tool software

bull FactoryTalk Activation server software

bull FactoryTalk Historian interface node

Optional software bull Microsoft Office 200x software

bull Antivirus software

bull Diskeeper software

bull OPC interface software

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

Engineering Workstation (EWS)

The engineering workstation (EWS) supports system configuration application development and maintenance functions This is the central location for monitoring and maintaining the systems operation

Computer Requirements - EWS

bull 30 GHz CPU

bull 3 GB memory

bull ATI video card

bull Dedicated Ethernet card

Software - EWS

Software Product

Operating system bull Windows XP Professional operating system

bull Windows 2003 Server operating system (if more than 10 nodes and activation server)

Control development software bull RSLogix 5000 Professional Edition software (includes Advanced Process Control function blocks)

bull RSLogix Architect software

bull RSLogix Emulate 5000 software

Visualization development software bull FactoryTalk View SE client software

bull FactoryTalk View Studio software

Batch development software (optional)(1) bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Recipe Editor software

bull FactoryTalk Batch View client software

Material management software (optional)(1) bull FactoryTalk Batch MaterialManager software

Asset management development software (optional)(1)

bull FactoryTalk AssetCentre client software

bull FactoryTalk AssetCentre audit support

Process information software (optional)(1) bull FactoryTalk Historian Process Book software

bull FactoryTalk Historian Datalink software

bull FactoryTalk Historian Batch View software

bull FactoryTalk Historian SQC software

bull FactoryTalk VantagePoint development tools

Operator Workstation (OWS)

The operator workstation (OWS) provides the graphical view and interface into the process The workstation is a client of either a PASS or application HMI server The OWS supports operator interaction and is not meant to support development or maintenance activities

Infrastructure software bull FactoryTalk Services Platform software

bull RSLinx Enterprise software

bull RSLinx Classic software(2)

bull FactoryTalk Security server software(1)

Optional configuration software bull Fuzzy Designer software

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) The EWS has the client and configuration tools You need the associated application server for runtime services

(2) Included with RSLogix 5000 Professional Edition software

Software - EWS

Software Product

Computer Requirements - OWS

bull 20 GHz CPU

bull 1 GB memory

bull ATI video card

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

Software - OWS

Software Product

Visualization software bull FactoryTalk View SE client software

Batch software (optional)(1) bull FactoryTalk Batch client software

bull FactoryTalk Batch eProcedure software

Process information software (optional)(1) bull FactoryTalk Historian Active View (ProcessBook) client software

bull FactoryTalk Activation client software

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

Computer Requirements - IndWS

bull 30 GHz CPU

bull 2 GB memory

bull ATI video card

bull UPS power backup recommended

Predefined Servers and Workstations

These servers and workstation are available as prepackaged hardware and software products based on the PlantPAx characterized system elements

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

Access engineering tools and associated documents fromhttprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=62366

Some downloads may require a TechConnect contract

Cat No Description

7477-IS2VS100 Process automation system server (PASS) with 100 screens

7477-IC2VC Operator workstation (OWS)

Category Tools

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

bull graphical objects for custom graphics and custom faceplates

Field instrument library Device integration tools provide access to isolated diagnostics and step-by-step guidance on connectivity configuration and commissioning of field devices with the PlantPAx system These tools includebull 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

Application development The Logix View utility is an engineering tool that helps you bulk generate portions of your application based on libraries of logic and human interface components 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

Contact your local office for this utility

Chapter 3

PlantPAx Field Device Integration and Asset Management

Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices

COMM STATUS

Channel A

Channel B

Asset Management

ControlNet Network

EtherNetIP Network

HART IO

CENTERLINEMotor Control

Center

EtherNetIP Network

PROFIBUS PA Network

PowerFlex Drives

Topic Page

EtherNetIP Devices 26

ControlNet Devices 27

DeviceNet Devices 28

HART Devices 30

FOUNDATION Fieldbus Devices 31

PROFIBUS PA Devices 33

Asset Management 35

Chapter 3 PlantPAx Field Device Integration and Asset Management

EtherNetIP Devices The Industrial Ethernet (EtherNetIP) network protocol is an open industrial-networking standard that supports both real-time IO messaging and message exchange The EtherNetIP network uses off-the-shelf Ethernet products and physical media

In a PlantPAx system the Ethernet IP provides the communication backbone for the supervisory network for the workstations servers and the controllers The EtherNetIP network can also function as a controller down link (remote IO network) but not with redundant controllers

EtherNetIP Products

Category Product Description

ControlLogix controller interface 1756-EN2T 1756-EN2F1756-ENBT1756-EWEB

Operates as ControlLogix EtherNetIP scanner

In-cabinet IO modules 1734 POINT IO 1734-AENT adapter

1794 FLEX IO 1794-AENT adapter

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

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

1738 ArmorPoint IO 1738-AENT adapter

Chassis-based IO modules 1756 ControlLogix IO 1756-EN2T 1756-EN2F or 1756-ENBT module

Soft motor starter 150 SMC Flex Built-in adapter

Variable frequency drive PowerFlex Use one of these optionsbull 20-COMM-E adapter

bull Embedded Ethernet port on PowerFlex 755 drive

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 modules

PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002

PowerFlex drives

httpwwwrockwellautomationcomencompass Encompass Program product directories

PlantPAx Field Device Integration and Asset Management Chapter 3

ControlNet Devices The ControlNet network is an open control network for real-time high-throughput applications The ControlNet network uses the Common Industrial Protocol (CIP) to combine the functionality of an IO network and a peer-to-peer network providing high-speed performance for both functions The ControlNet network gives you deterministic repeatable transfers of all mission-critical control data in addition to supporting transfers of non-time-critical data IO updates and controller-to-controller interlocking always take precedence over program uploads and downloads and messaging

In a PlantPAx system the ControlNet network is recommended for controller downlinks and connections to remote IO and field device interfaces The ControlNet network supports both standard and redundant architectures

ControlNet Products

ControlLogix controller interface 1756-CN2 1756-CN2R1756-CNB 1756-CNBR

Operates as ControlLogix ControlNet scanner

In-cabinet IO modules 1734 POINT IO 1734-ACNR adapter (redundant)

1794 FLEX IO Use one of these adaptersbull 1794-ACN15 adapter

bull 1794-ACNR15 adapter (redundant)

bull 1794-ACN15K adapter conformal coated

bull 1794-ACNR15K adapter (redundant) conformal coated

1797 FLEX Ex intrinsically safe IO Use one of these adaptersbull 1797-ACNR15 adapter (redundant)

bull 1794-ACN15 adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)

bull 1794-ACNR15 adapter (redundant use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous area)

On-machine IO modules 1738 ArmorPoint IO 1738-ACNR adapter with TNC connector (redundant)

Chassis-based IO modules 1756 ControlLogix IO Use one of these adaptersbull 1756-CN2 adapter

bull 1756-CN2R adapter (redundant)

bull 1756-CNB adapter

bull 1756-CNBR adapter (redundant)

Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter

bull 20-COMM-Q fiber adapter

DeviceNet Devices The DeviceNet network is an open low-level network that provides connections between simple industrial devices (such as sensors and actuators) and higher-level devices (such as PLC controllers and computers) The DeviceNet network uses the proven Common Industrial Protocol (CIP) to provide the control configuration and data collection capabilities for industrial devices

In a PlantPAx system the DeviceNet network connects networked control devices

PowerFlex drives

DeviceNet Products

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 isolator and 1797-CEC connector to connect to hazardous areas)

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)

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

Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing

Use E1 Plus or E3 electronic overload relay

Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter

XM condition monitoring specialty modules

1440 Emonitor modules Built-in adapter

DeviceNet Products

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

Embedded IO For DeviceNet Technical Data publication 1799-TD001

1799 Embedded IO products

PowerFlex drives

HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners

PlantPAx systems interface directly with HART instruments through HART-capable distributed IO modules

HART technology provides digital data (diagnostic information) in addition to analog Device integration tools provide access to isolated diagnostics and step-by-step guidance on connectivity configuration and commissioning of Endress+Hauser HART field devices with the PlantPAx system These tools include

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

HART Products

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

bull DTMs

1769-sc-IF4IH1769-sc-OF4IH

Spectrum Compact IO modules

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

FOUNDATION Fieldbus Devices

The FOUNDATION Fieldbus network is a communication network created by the Fieldbus Foundation It is a protocol designed for robust distributed control of process control applications Devices connected by a FOUNDATION Fieldbus network can be used for sophisticated highly-distributed process control

PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNetIP and ControlNet linking devices

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

FOUNDATION Fieldbus Products

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 four outputs eight 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

The FOUNDATION Fieldbus network offers the ability for devices to share information with each other Control in the field is possible on the same segment and the segment will continue to run even without the control system Field device data can also be accessed via an OPC server Device integration tools provide access to isolated diagnostics and step-by-step guidance on connectivity configuration and commissioning of Endress+Hauser FOUNDATION Fieldbus field devices with the PlantPAx system These tools include

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

HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 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 4 6 810 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

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

PlantPAx systems communicate with PROFIBUS PA devices through the EtherNetIP-to-PROFIBUS PA linking device

PROFIBUS PA Products

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

PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module four outputs eight inputs intrinsically safe

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

PROFIBUS PA device integration uses the 1788HP-EN2PA module as an Ethernet PA master linking directly to the PA bus and connecting PA field devices to the ControlLogix controller Device integration tools provide access to isolated diagnostics and step-by-step guidance on connectivity configuration and commissioning of Endress+Hauser PA field devices with the PlantPAx system These tools include

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-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway four 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 four segments

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

KT-MB-GTR-2PA Compact segment coupler kit - two 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 the PROFIBUS PA network Mount inside cabinet Terminals for 4 6 810 and 12 spurs

Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices

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

Asset Management Server

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

Computer Requirements - Asset Management Server

bull 30 GHz CPU

bull 2 GB memory

Software - Asset Management Server

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

Asset Management Products

FactoryTalk AssetCentre asset management provides a set of asset-centric tools to help you to manage your automation and process investment

bull The process device configuration tool uses Field Device Type (FDT) technology to access instrument parameters configure and commission process devices and help with diagnostics

bull The calibration management tool provides a paperless calibration solution that manages calibration requirements specifications schedules calibration results and reports The calibration management tool uses the Field Calibrator Interface (FCINTF) to interface with calibrators from a variety of vendors

FCINTF

FactoryTalk AssetCentre Server software 9515-ASTSRVRENE FactoryTalk AssetCentre Server

Additional assets 9515-ASTCAPxxxxE FactoryTalk AssetCentre assets where xxxx=0005 0025 0100 0500 1000 or 5000

Process device configuration tool bull 9515-ASTPRDCFENE FactoryTalk AssetCentre Process Device Configuration

Calibration management tool bull 9515-ASTCLMANENE FactoryTalk AssetCentre Calibration Management software

bull 9515-ASTCLWRKENE FactoryTalk AssetCentre Calibration Management remote workstation

bull 9515-ASTCLFLKENE FactoryTalk AssetCentre Calibration Management FLUKE interface

bull 9515-ASTCLDRKENE FactoryTalk AssetCentre Calibration Management Druck interface

bull 9515-ASTCLTMNENE FactoryTalk AssetCentre Calibration Management Trnsmtn interface

Calibrators Loop705 707 707Ex 715

Fluke handheld process-loop calibrators for the calibration and troubleshooting of 420 mA process control loops

Multifunction725 741 743B 744

Fluke handheld multifunction calibrators for temperature pressure voltage and mA parameters

Pressure717 718 718Ex 719

Fluke pressure calibrators measure pressure to 005 DC mA The 718 and 718Ex have an onboard pump Ranges 30 and 100 PSIG

Temperature712 714 724

Fluke temperature calibrators include712 RTD sourcemeasure714 thermocouple (TC) sourcemeasure724 sourcemeasure RTD TC measure mA 24V loop

Chapter 4

PlantPAx Batch Management and Control

Introduction PlantPAx batch management and control solutions offer flexible production equipment-independent recipe management batch-independent equipment control and regulatory compliance Operation functions provide batch visualization analysis and web-based reporting These scalable integrated solutions meet industry standards to meet small basic batchsequencing needs as well as distributed comprehensive batchsequencing needs

COMM STATUS

CNet Barrier In

Channel A

Channel B

Operator Workstation

System Printers

ControlNet Network

EtherNetIP Network

Remote IO Racks

HART IO

Application ServerBatch

Management

Application Server

Material Management

Topic Page

Basic Batch and Sequencing 39

Comprehensive Batch and Sequencing 41

Material Management 44

Chapter 4 PlantPAx Batch Management and Control

Batch Management amp Control is a critical component of many process applications Diverse batch processing needs range from simple single vessel single product manufacturing to complex multi-path multi-vessel multi-product manufacturing Each need requires a different recipe and management approach such as solutions for

bull fixed sequences fixed formulation and simple equipment controlbull flexible sequences flexible formulations multiple unit coordinationbull flexible sequences flexible formulation multiple unit coordination and

networked pathway coordination

Batch management and control also addresses other business and production functions such as

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

The PlantPAx system supports basic batch and sequencing capabilities for small systems through core system functions as well as comprehensive batch and sequencing capabilities for complex systems through modular server and software components The PlantPAx portfolio is scalable to meet a wide range of batch and sequencing requirements from small to large simple to complex

PlantPAx Batch Management and Control Chapter 4

Basic Batch and Sequencing

Basic batch and sequencing extends core system components to provide batch capabilities for smaller systems

bull PhaseManager softwarebull HMI faceplates

Redundant Controller Pair

Distributed IO Racks

FOUNDATION Fieldbus Links

ControlNet Links

The basic batch and sequencing options rely on programming to manage the application

Basic Batch and Sequencing Options

Option Description

Coded (custom) Coded solutions rely on core system Logix functionality (PhaseManager software and the sequential function chart SFC language) to provide basic sequencing in the controller This solution offers the capability for small systems to adapt standards without the overhead of more complex batch management and control functionality PhaseManager software provides a repeatable code organization model The SFC language is the fixed sequencing mechanism

Generally these solutions are optimized for fixed sequences fixed formulation and simple equipment control local to the process

Configured Configured solutions extend core Logix functionality (PhaseManager software) and FactoryTalk View functionality (standard faceplates) to provide basic batch management and control functionality in the controller and HMI This solution offers the capability for small systems to adapt standards provides local formulation management and enables flexible sequence definition without the overhead of more comprehensive server-based solutions PhaseManager software is the basis for process control code A standard set of HMI faceplates and the process controller provide recipe management and unit supervision local to the controller without the need for custom code

Generally these solutions are optimized for flexible sequences flexible formulation and simple equipment control local to the process

Coded Batch and Sequencing Products

Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant

controller

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

Control logic PhaseManager software Create custom code forbull recipe management (formulas sequences and

equipment)

bull batch and sequence control

Visualization OWS with FactoryTalk View SE software Create custom displays

Comprehensive Batch and Sequencing

Add comprehensive batch and sequencing capability to the core PlantPAx system with software-based supervisory batch management and control for large and complex applications These multi-unit multi-controller batch management and control solutions

bull give the ability develop and manage recipes through standard softwarebull meet the demands of validated industriesbull provide for manual work instructionsbull enable active material managementbull connect to manufacturing and business systemsbull enable collection and storage of contextual batch information

Comprehensive batch and sequencing solutions leverage core Logix functionality (PhaseManager software) in conjunction with batch software (FactoryTalk Batch software) PhaseManager software continues to be the basis for process control code in the controller FactoryTalk Batch software provides recipe management information management process management and unit supervision

Configured Batch and Sequencing Products

controller

Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates

Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)

Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources

Available as a process object application

Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)

Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources

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

There are options depending on system size and batch server location

ControlNet Links

OWSEWS Batch Server

ControlLogix Chassis with 56SAM-838 Module

Application Server Batch Management

Option Description

Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems

The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software

Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements

The application batch server is a Windows-based server on which you install batch server software

You might also need abull material management serverbull information management server

Computer Requirements - Batch Server

56SAM-838 server bull 1 GB memory

bull 8 GB CompactFlash card

Application server bull Pentium 4 processor or better

bull 30 GHz CPU

bull 2 GB memory

Software - Batch Server

Software Product

Batch software bull FactoryTalk Batch server software

bull FactoryTalk Batch Equipment Editor software

bull FactoryTalk Batch Client software

bull FactoryTalk Batch Archiver software

Infrastructure software bull FactoryTalk Services Platform client

bull RSLinx Classic software

Material Management The material management extension of batch management and control provides an active material management and inventory system This includes material-based phase definitions in batch execution that enables just-in-time material and equipment selection to provide flexible batch manufacturing and real-time production scheduling

Material Management Server

The material manager server integrates with company-wide inventory management systems The server complements ERP-level resource management by collecting the detailed material and equipment tracking information

Application Servers (redundant) - Batch Management

Application Servers (redundant) - Material Management

Controller and Field Device Interfaces

EtherNetIP Network

Link to Distributed IO

Software - Material Management Server

bull 30 GHz CPU

bull 2 GB memory

Software Product

Material management software bull FactoryTalk Batch MaterialManager server software

Supported third-party software bull Symantec Antivirus software

Chapter 5

PlantPAx Process Information

Introduction A PlantPAx system employs a distributed data management strategy The process information extension provides the tools to collect store and analyze that data from a central location

The PlantPAx process information solution offers an integrated set of decision-making tools and dashboards that help provide real-time access to and analysis of process and production information throughout the enterprise

bull Produce web-based KPI dashboards and reportsbull Deliver timely information throughout manufacturingndashderived from

various manufacturing processes

COMM STATUS

CNet Barrier In

Channel A

Channel B

System Printers

ControlNet Network

EtherNetIP Network

Remote IO Racks

HART IO

EtherNetIP Network

Management

Application Server

Material Management

Application Server Information Management

Chapter 5 PlantPAx Process Information

Information Management An information management server manages the decision-making tools and dashboards that provide real-time and historical access to and analysis of process information The information management server manages both

bull data managementbull decision support

Information Management Server Products

Historical data bull FactoryTalk Historian software

bull FactoryTalk Alarms and Events software

bull FactoryTalk Batch software

These application managebull distributed data collection to collect and verify contextual

process data

bull storage management to reliably and efficiently store data with easy access

Decision support FactoryTalk VantagePoint software The decision support functions providebull comprehensive view of plant operations

bull presentation analysis and reporting resources

Computer Requirements - Historical Data Server

bull 30 GHz CPU

bull 2 GB memory

PlantPAx Process Information Chapter 5

Software - Historical Data Server

Software Product

Data management software bull FactoryTalk Historian server software

Decision support software bull FactoryTalk VantagePoint software

bull Microsoft reporting services

bull MSSQL Server software

bull SQL Server 2005 software (can be remote)

bull FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software

bull Concurrent or Named User client licenses

bull Data source connectors for databases and enterprise applications

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 objectivesmdashcost reductions decreased emissions consistent quality and production increasesmdashevery 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

66 1100 13

25253333

39395050

646470

SoftSensors

ControllerMetrics

Console

SCADAHMIServices

ControlSystems

MESSystems

CustomDatabase

PlantHistorians

SPCSQCSystems

LaboratorySystems

MaintenanceSystems

Dynamic MPC

Chapter 6 PlantPAx Plantwide Optimization

Pavilion Platform

Use the Pavilion platform within a PlantPAx system to add model predictive control environmental performance management and production performance management

Computer Requirements - Pavilion Platform

Client hardware 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

Control application hardware bull Pentium III processor

bull 500 MHz CPU

bull 1 GB memory

Software - Pavilion Platform

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 Pavilion8 Model Predictive Control software

Chapter 7

PlantPAx Critical Process Control and Safety Systems

Introduction The combination of Rockwell Automation and ICS Triplex a Rockwell Automation company products the PlantPAx system supports expanded process safety offerings that provide high levels of availability and of safety and critical process control

SIL 2 Controller for Fail Safe or Fault Tolerance

Safety System Development Workstation

(IsaGraph)

Scalable Controller for SIL 2 and SIL Fail Safe and Fault Tolerance

TMR SIL 3 Safety Controller and IO

1400 Termination Board

Topic Page

High Availability Systems 54

ControlLogix SIL 1 and SIL 2 Systems 55

ICS Triplex SIL 2 and SIL 3 Systems 58

Chapter 7 PlantPAx Critical Process Control and Safety Systems

High Availability Systems Critical processes requires systems with high availability 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)

MTBF = Mean Time Between Failure

MDT = Mean Down Time

High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired

Redundant ControlLogix Controllers

Redundant Network Media

Redundant Servers Redundant Workstations

PlantPAx Critical Process Control and Safety Systems Chapter 7

ControlLogix SIL 1 and SIL 2 Systems

Safe reliable systems safeguard people property the environment and reputations Safety Integrity Level certification makes it simpler easier and less expensive to meet growing standards compliance requirements worldwide

Common ControlLogix components and tools help customers lower lifecycle costs for both process control and for separate independent safety instrumentation The SIL 2 certification of ControlLogix products assures the suitability of ControlLogix components development tools networks and databases for use in safety applications up to and including SIL 2

The following examples show ControlLogix configurations that meet SIL 1 and SIL 2 certifications for fail safe and fault tolerant requirements

High Availability Products

Product Description

Process controller Redundant ControlLogix 1756-L63 controllersbull Firmware revisions 1656 and 1680

bull Redundant Add-On Instructions

IO modules bull 1756 discrete analog specialty and HART modules

bull 1794 FLEX IO discrete analog specialty and HART modules

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

bull 1757-SRM

bull 1756-ENBT

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

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

Sensor

Actuator

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

Fail Safe Configuration

SIL Rated Instruments

Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates

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

Actuator

Overall Safety Loop

This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)

Product Description

SIL 2 Endress+Hauser instruments bull Promass 83 Coriolis mass flow

bull Prowirl 73 Vortex flow

bull Levelflex M FMP40 guided radar level

bull Micropilot M FMR240 radar level

bull iTEMP TMT182 temperature transmitter

SIL 3 Endress+Hauser instruments bull Cerabar S PMC71 pressure

bull Deltabar S PMD75 differential pressure

ICS Triplex SIL 2 and SIL 3 Systems

ICS Triplex systems use a triple modular redundant (TMR) architecture Triple redundancy eliminates the possibility of any single component failure causing a spurious or false trip ICS Triplex integration with PlantPAx systems includes OPC connectivity to FactoryTalk applications and CIP connectivity including profile support in RSLogix 5000 software

Both the Trusted and AADvance systems share a common EthernetIP network within a PlantPAx system In addition the AAdvance system supports the CIP producerconsumer communication protocol

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

httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e

Complete list of SIL rated instruments from Endress+Hauser

AADvance Safety Control System

IsaGraph Development Workstation

Trusted TMR Control System

ICS Triplex technology is available only as a complete system from ICS Triplex a Rockwell Automation company For information see httpwwwicstriplexcom

ICS Triplex Products

Product Description

Trusted system Trusted technology uses 3-3-2-0 fault-tolerant control to virtually eliminate spurious trips Triple modular redundancy (TMR) uses majority voting to identify a source of failure Available with OPC or CIP integration

AADvance system The AADvance technology isbull configurable for SIL 2 and SIL 3

bull scalable redundancy for fault tolerance

bull simplex duplex or triplex configuration

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 sensemdashdelivering maximum value without relying on proprietary hardware and software

Domain Controller A domain controller manages access to network resources (such as applications and printers) for a group of users Each user need only to log in to the domain to gain access to the resources which may be located on a number of different servers in the network

Topic Page

Domain Controller 61

Ethernet Hardware 62

System Software and Services 63

Computer Requirements - Domain Controller

Hardware 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

Chapter 8 PlantPAx Infrastructure

Follow these guidelines for the domain controllerbull A domain controller is required if there are 10 or more Ethernet nodes

(IP addresses)bull The domain controller is a separate computer Do not load any

application software on the domain controller Load all system application software on the other computers such as the PASS application server OWS and EWS

bull Microsoft support does not recommend running applications on the domain controllers and certainly not applications that require more than Authenticated User privileges to run

bull The domain controller must be local to the system workstations and servers (within the local firewall) and not remote to the system

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

Hardware Product

Stratix switches In the core system to effectively manage real-time control and information flow Stratix Ethernet switches integrate Cisco technology to support flexible topologiesbull Stratix 8300 layer 3 (supervisory) modular managed switches

bull Stratix 8000 layer 2 (supervisory) 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 includebull Layer 2 managed switch such as Cisco Catalyst 2950 series or equivalent Rockwell

Automation approved switch (Encompass partner)

bull Layer 3 managed switch such as Cisco Catalyst 3760 series or equivalent Rockwell Automation approved switch (Encompass partner)

PlantPAx Infrastructure Chapter 8

System Software and Services

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

Software Description

FactoryTalk Security software Provides a wide range of security services that are integrated into the FactoryTalk Directory services FactoryTalk Security services provide centralized authentication and access 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

Chapter 9

PlantPAx Migration Tools

Introduction Rockwell Automation provides a DCS migration program to assist customers and integrators with migrating legacy DCS systems to PlantPAx systems Rockwell Automation works internally and with partners to develop tools and to support migration and conversion projects This program also works to develop engineering competence and capacity within Rockwell Automation and its partners for planning executing and supporting DCS migration projects

Rockwell Automation supports the migration of these systems to PlantPAx systems

bull ABB (Bailey) Net90 and Infi90 control systemsbull Honeywell TDC 2000 TDC 3000 and TPS systemsbull Honeywell IPC620 programmable logic controllers bull Emerson (Fisher Controls) PROVOX systemsbull Invensys (Foxboro) IA systems bull Rockwell Automation ProcessLogix (PLx) systems

For each system there is a general migration plan that describes the particular goals and methods for system migration as well as specifics on the tools currently available for migrating that system

Other systems for which Rockwell Automation has tools and services include bull Emerson (Westinghouse) WDPF and WDPF II systemsbull NovaTech D3 systems (original company (EMC ndash Electronic Modules

Corp) and its technology (S3 and D3) went through multiple acquisitions including Rexnord Banner Texas Instruments and GSE)

bull Siemens (Moore) APACS systemsbull Schneider (Square D ndash originally Crisp Automation) CRISP systems

Rockwell Automation provides extensive migration and integration capabilities for PLC-based systems and other third-party systems

Chapter 9 PlantPAx Migration Tools

Migration Tools Migration tools take the following forms bull Products that become a part of the system during a migration or may

become a permanent part of the target solution such as IO cables IO scanners and application codes

bull Utilities that assist with converting engineering information from the original control system to a PlantPAx system such as database conversion utilities

bull Services that provide engineering and logistical support to migration projects to assist with converting engineering configuration and applications to the PlantPAx environment such as manual database conversions and operator graphics conversions

The following table presents a description of tools available for legacy DCS migration support Not all tools are available for each target legacy DCS system

Available Migration Tools

System Function Tool

ABB Bailey Net90 and Infi90

Communication RoviSys OPC90 server

Online Development RA56-cATM-BLY90 Bailey-to-Logix interface module (1756 form factor software preloaded)

Database conversion Rockwell Automation Bailey database conversion utility

Faceplates Rockwell Automation Bailey faceplate library

Application code Rockwell Automation Bailey control strategy library (Add-On Instructions)

IO interface Rockwell Automation Bailey termination cables

HoneywellTDC2000 and TDC3000

Communication Matrikon OPC server for Honeywell APP node

Database conversion Rockwell Automation Honeywell database conversion utility

Application conversion and simulation

Quest Honeywell MFC shadow module (ControlLogix application shadows a MFC application)

IO interface Rockwell Automation IPC620 IO scanner

Rockwell Automation TDC 2000 termination cables

Rockwell Automation TDC20003000 termination cables

ProSoft MVI56-DEM module (1756 form factor) integrates multiple Honeywell DE smart instruments (including ST3000 smart pressure transmitter) to ControlLogix sysem

PlantPAx Migration Tools Chapter 9

EmersonFisher-Rosemount PROVOX

Communication Matrikon PROVOX direct OPC server for Data Highway access via HDL

Online Development PROVOX Data Highway interface with RA56-SAM module

Database conversion Rockwell Automation PROVOX database conversion utility

Faceplates Rockwell Automation PROVOX faceplate library

Application code Rockwell Automation Emerson control strategy library (Add-On Instructions)

IO interface Quest PROVOX S10S20 IO scanner

Rockwell Automation PROVOX termination cables

InvensysFoxboro IA

Communication Matrikon Foxboro IA server

Online Development Foxboro IA Data Highway interface with RA56-SAM module

Database conversion Rockwell Automation Foxboro IA database conversion utility

Rockwell AutomationProcessLogix

Communication Standard connections between ProcessLogix and PlantPAx systems

Database conversion Rockwell Automation ProcessLogix database conversion utility

IO interface IO is already Logix-based IO

SiemensMoore APACS

IO Interface Rockwell Automation APACS termination cables

Emerson Westinghouse WDPF and WDPF II

IO Interface Rockwell Automation WDPF and WDPF II termination cables

EmersonRosemount RMV9000

IO Interface Rockwell Automation RMV9000 termination cables

ABBTaylor MOD300 and Advant OCS

IO Interface Rockwell Automation IO scanner interface for TRIO remote IO

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

Rockwell Automation Support

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

Installation Assistance

If you experience an anomoly within the first 24 hours of installation review the information that is contained in this manualYou can contact Customer Support for initial help in getting your product up and running

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures

Documentation Feedback

Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA-DU002 available at httpwwwrockwellautomationcomliterature

United States or Canada 14406463434

Outside United States or Canada

Use the Worldwide Locator at httpwwwrockwellautomationcomsupportamericasphone_enhtml or contact your local Rockwell Automation representative

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

Outside United States Please contact your local Rockwell Automation representative for the return procedure

PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide

Important User Information

Table of Contents

1 - PlantPAx Process Automation System Overview

Introduction


Architecture Classes





2 - PlantPAx Core System

Introduction

Core Control Hardware








Engineering Tools

3 - PlantPAx Field Device Integration and Asset Management

Introduction

EtherNetIP Devices


ControlNet Devices


DeviceNet Devices


HART Devices




PROFIBUS PA Devices


Asset Management



4 - PlantPAx Batch Management and Control

Introduction



Material Management


5 - PlantPAx Process Information

Introduction

Information Management

6 - PlantPAx Plantwide Optimization

Introduction

Pavilion Platform

7 - PlantPAx Critical Process Control and Safety Systems

Introduction

High Availability Systems







8 - PlantPAx Infrastructure

Introduction

Domain Controller

Ethernet Hardware


9 - PlantPAx Migration Tools

Introduction

Migration Tools


Back Cover