PlantPAx Process Automation System · PlantPAx Process Automation System Overview Chapter 1 Process...
Transcript of PlantPAx Process Automation System · PlantPAx Process Automation System Overview Chapter 1 Process...
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
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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
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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
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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
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Chapter 1 PlantPAx Process Automation System Overview
The PlantPAx system focuses on these main areas
PlantPAx System Focus Areas
Focus Area Description
Core system The PlantPAx core system consists 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
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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
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Chapter 1 PlantPAx Process Automation System Overview
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PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
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Chapter 1 PlantPAx Process Automation System Overview
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
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PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
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Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
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PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
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Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
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PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
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Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
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Chapter 2
PlantPAx Core System
Introduction The PlantPAx core system consists of the components required to engineer and maintain a process system This includes system servers workstations and controllers The core system also includes interfaces to field devices including IO modules linking devices and bridges as well as the network infrastructure
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
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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
bull 1756-CNB 1756-CNBR
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
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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
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Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
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PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
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Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Important User InformationSolid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls (publication SGI-11 available from your local Rockwell Automation sales office or online at 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
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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
6 Publication PROCES-SG001B-EN-P - September 2009
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
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
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Chapter 2
PlantPAx Core System
Introduction The PlantPAx core system consists of the components required to engineer and maintain a process system This includes system servers workstations and controllers The core system also includes interfaces to field devices including IO modules linking devices and bridges as well as the network infrastructure
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
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PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
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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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
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
5Publication PROCES-SG001B-EN-P - September 2009 5
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
6 Publication PROCES-SG001B-EN-P - September 2009
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
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
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
5Publication PROCES-SG001B-EN-P - September 2009 5
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
6 Publication PROCES-SG001B-EN-P - September 2009
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
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
5Publication PROCES-SG001B-EN-P - September 2009 5
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
6 Publication PROCES-SG001B-EN-P - September 2009
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
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
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Chapter 8
PlantPAx Infrastructure
Introduction The PlantPAx system infrastructure is built on open industry standards to support seamless integration of the system components as well as to provide connectivity to higher-level business systems In addition the PlantPAx system leverages best-of-breed technology partners where it makes 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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
6 Publication PROCES-SG001B-EN-P - September 2009
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
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Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
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Chapter 6 PlantPAx Plantwide Optimization
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
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
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
8 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
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PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
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PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 9
PlantPAx Process Automation System Overview Chapter 1
Architecture Classes Rockwell Automation leverages Integrated Architecture technologies and products to create a scalable process architecture The flexibility and compatibility built into these products enable them to be applied standalone as independent products ideal for original equipment manufacturer (OEM) process equipment or integrated as a distributed automation system ideal for processing facilities
Rockwell Automation characterizes a process automation system based on its scope or architecture class Architecture classes provide a way to define system capabilities that can be scaled by modifying the same system elements
bull Independent system architecture for unit controlbull Centralized system architecture for area controlbull Distributed system architecture for plant-wide and enterprise operations
Independent
Centralized
Distributed
Single Server Single Client
Single Server Multiple Clients
Multiple Servers Multiple Clients
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
10 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
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Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
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Chapter 6 PlantPAx Plantwide Optimization
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 11
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example independent class architecture
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
12 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
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
strategies (loops) per controller with a system maximum of 500 control strategies
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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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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
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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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 13
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example centralized class architecture
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
14 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Distributed Class Architecture Example
The distributed class architecture expands on the centralized class by adding application servers to interconnect multiple process areas into a system The 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
strategies (loops) per controller with a system maximum of 2000 control strategies
bull 64 IO modules nominally on a 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
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 Multiple MWS as laptops
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 15
PlantPAx Process Automation System Overview Chapter 1
This diagram shows an example distributed class architecture
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
16 Publication PROCES-SG001B-EN-P - September 2009
Chapter 1 PlantPAx Process Automation System Overview
Recommended Architecture Sizes
Use these system elements in your process architecture
System Element Independent Class Centralized Class Distributed Class
Independent workstation
Independent workstation (single computer) functions 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
bull Can have as many as 5 EWS
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
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
One PASS required and includesbull FactoryTalk Directory server
bull HMI server
bull Data server
PASS supportsbull 1000 display points per
OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
Application servers None One batch server One batch server for each set of six controllersThree AppSer-HMI each with
bull 1000 display points per OWS
bull 1000 alarms with Acks per controller
bull 50 data log points logged per second per controller
OWS Included in independent workstation
8 remote clients 8 remote clients for PASS8 additional remote clients per AppSer-HMI
Domain controller 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
(loops) per controller at a 250 ms period
bull 500 total control strategies per system
16 ControlLogix controllers per PASS16 ControlLogix controllers per AppSer-HMI
bull 125 control strategies (loops) per controller at a 250 ms period
bull 2000 total control strategies per system
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
17Publication PROCES-SG001B-EN-P - September 2009 17
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
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
FOUNDATION Fieldbus Network
Topic Page
Core Control Hardware 18
Core Servers and Workstations 19
Engineering Tools 23
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
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Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
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Chapter 6 PlantPAx Plantwide Optimization
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
18 Publication PROCES-SG001B-EN-P - September 2009
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
bull 1756-CNB 1756-CNBR
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
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
-
- Introduction
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 19
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
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
-
- Introduction
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
20 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 3 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
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
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 21
PlantPAx Core System Chapter 2
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 FactoryTalk View Administration Console software
bull RSLinx Enterprise software
bull RSLinx Classic software(2)
bull FactoryTalk Activation server software
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
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The EWS has the client and configuration tools You need the associated application server for runtime services
(2) Included with RSLogix 5000 Professional Edition software
Software - EWS
Software Product
Computer Requirements - OWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 20 GHz CPU
bull 1 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
22 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Independent Workstation
The independent workstation (IndWS) is a single computer that contains allthe system software to develop operate and maintain an independent processapplication The IndWS integrates the functions of multiple servers (PASS andother application servers) and workstations (EWS and OWS) into onecomputer
Software - OWS
Software Product
Operating system bull Windows XP Professional operating system
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
Infrastructure software bull FactoryTalk Services Platform software
bull FactoryTalk Activation client software
Optional software bull Microsoft Office 200x software
bull Antivirus software
bull Diskeeper software
(1) The OWS has the client and configuration tools You need the associated application server for runtime services
Computer Requirements - IndWS
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull ATI video card
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 23
PlantPAx Core System Chapter 2
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-IS2VS250 Process automation system server (PASS) with 250 screens
7477-IC2VC Operator workstation (OWS)
Category Tools
Process control library Rockwell Automation branded and supported library of building blocks that support process devices (such as valve motor and transmitter) consisting 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
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
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Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
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Chapter 8
PlantPAx Infrastructure
Introduction The PlantPAx system infrastructure is built on open industry standards to support seamless integration of the system components as well as to provide connectivity to higher-level business systems In addition the PlantPAx system leverages best-of-breed technology partners where it makes 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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
24 Publication PROCES-SG001B-EN-P - September 2009
Chapter 2 PlantPAx Core System
Notes
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
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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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
25Publication PROCES-SG001B-EN-P - September 2009 25
Chapter 3
PlantPAx Field Device Integration and Asset Management
Introduction Field device components include interfaces instruments actuators drives and field devices These components include DeviceNet HART FOUNDATION Fieldbus and PROFIBUS PA devices
COMM STATUS
In
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Asset Management
ControlNet Network
Redundant Controllers
EtherNetIP Network
Intrinsically Safe Area
HART IO
XM Condition Monitoring
CENTERLINEMotor Control
Center
FOUNDATION Fieldbus Network
EtherNetIP Network
PROFIBUS PA Network
Intrinsically Safe Area
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
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
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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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
26 Publication PROCES-SG001B-EN-P - September 2009
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
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO modules
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 27
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
Category Product Description
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)
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive owerFlex Use one of these adaptersbull 20-COMM-C coax adapter
bull 20-COMM-Q fiber adapter
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
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Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
28 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
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
DeviceNet Products
Category Product Description
ControlLogix controller interface 1756-DNB Operates as ControlLogix DeviceNet scanner
In-cabinet IO modules 1734 POINT IO Use one of these adaptersbull 1734D POINTBlock series interface with integrated IO
bull 1734-ADN adapter
bull 1734-ADNX adapter with subnet connectivity
bull 1734-PDN communication interface
1790 CompactBlock LDX IO Built-in adapter in base block
1791D CompactBlock IO Built-in adapter in base block DeviceLogix Smart Component Technology
1794 FLEX IO 1794-ADN adapter
1797 FLEX Ex intrinsically safe IO 1794-ADN adapter (use with 1797-BIC isolator and 1797-CEC connector to connect to hazardous areas)
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
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Chapter 6 PlantPAx Plantwide Optimization
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 29
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
On-machine IO modules 1732 ArmorBlock IO Built-in adapter in base block
1738 ArmorPoint IO Use one of these adaptersbull 1738-ADN12 adapter with M12 quick-disconnect
terminations
bull 1738-ADN18 adapter with mini connector (drop)
bull 1738-ADN18P adapter with mini connector (pass-thru)
bull 1738-ADNX adapter with subnet connectivity
1792 ArmorBlock MaXum IO Built-in adapter in base block DeviceLogix Smart Component Technology
1799 Embedded IO Built-in adapter DeviceLogix Smart Component Technology
Chassis-based IO modules 1756 ControlLogix IO 1756-DNB module
1762 MicroLogix expansion IO 1761-NET-DNI linking device
1769 Compact IO 1769-ADN adapter
1771 PLC-5 IO 1771-SDN module
Full-voltage motor starters 193 full-voltage nonreversing592 full-voltage nonreversing
Use E1 Plus or E3 electronic overload relay
Soft motor starter 150 SMC Flex Built-in adapter
Variable frequency drive 20B PowerFlex 700 20-COMM-D adapter
XM condition monitoring specialty modules
1440 Emonitor modules Built-in adapter
DeviceNet Products
Category Product Description
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
NetLinx Selection Guide publication NETS-SG001 EtherNetIP ControlNet and DeviceNet network components
POINT IO Selection Guide publication 1734-SG001 1734 POINT IO modules
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
ArmorBlock MaXum IO and ArmorBlock IO Selection Guide publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock IO modules
ArmorPoint IO Selection Guide publication 1738-SG001 1738 ArmorPoint IO module
Embedded IO For DeviceNet Technical Data publication 1799-TD001
1799 Embedded IO products
PowerFlex Logw Voltage Drives Selection Guide publication PFLEX-SG002
PowerFlex drives
httpwwwrockwellautomationcomencompass Encompass Program product directories
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
30 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
HART Devices Highway Addressable Remote Transmitter (HART) is an open protocol designed to connect analog devices For HART connectivity select from products available from Rockwell Automation and our Encompass partners
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
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
HART Products
Category Product Description
Chassis-based IO modules 1756-IF8H1756-OF8H
ControlLogix analog IO modules withbull standard profiles in RSLogix 5000 software
bull DTMs
MVI56-HART Prosoft ControlLogix IO module
Distributed IO modules 1794-IE8H1794-OE8H1794-IF8IH1794-OF8IH
1797-IE8H1797-OE8H
FLEX 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
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 31
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
FLEX IO and FLEX Ex IO Selection Guide publication 1794-SG002 1794 FLEX and 1797 FLEX Ex IO modules
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument Data in FactoryTalk View SE Knowledgebase document (Login required Please contact your sales representative)
httprockwellautomationcusthelpcomcgi-binrockwellautomationcfgphpenduserstd_adpphpp_faqid=54857
How to implement the HART Add-On Instruction in controller logic to work with the FactoryTalk View faceplates for HART instruments
FOUNDATION Fieldbus Products
Category Product Description
EtherNetIP interface 1757FFLD21757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports
ControlNet interface 1757-FFLDC21757-FFLDC4
Bridge from a ControlNet network to either two or four H1 ports compatible with ControlLogix redundancy and redundant ControlNet media
FOUNDATION Fieldbus network components
FD0-VC-Ex4FF Pepperl+Fuchs discrete IO module 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
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
32 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products KLD2-FBPS-125360 Pepperl+Fuchs FOUNDATION Fieldbus 360 mA 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
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per FOUNDATION Fieldbus H1 segment
MB-FB-x Pepperl+Fuchs power hub motherboard available inbull 1R one redundant segment
bull 2R two redundant segments
bull 4 four segments
bull 4R four redundant segments
MBHD-FB-4R Pepperl+Fuchs high-density power hub four redundant segments
HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on FOUNDATION Fieldbus H1 segments and outputs a collective fault signal
Segment protection R2-SP-Nx Pepperl+Fuchs segment protector provides current limiting nonincendive energy to FOUNDATION Fieldbus H1 Mount inside cabinet Terminals for 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
FOUNDATION Fieldbus Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
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Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
-
- Introduction
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 33
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
PROFIBUS PA Products
Category Product Description
PROFIBUS interface 1788HP-EN2PA HIPROM ControlLogix EtherNetIP to PROFIBUS PA linking device
PROFIBUS network components FD0-VC-Ex4PA Pepperl+Fuchs discrete IO module 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 PROFIBUS PA intrinsically-safe terminator which screws into a 12 in NPT transmitter port
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
34 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
bull pre-engineered controller code with Add-On Instructions that provide two-way exchange of data between faceplates and the ControlLogix controller
bull pre-configured operator faceplates that provide visualization of instruments connected to the network interface
bull integration documentation that describes the implementation
Power conditioning products HD2-DM-A Pepperl+Fuchs advanced diagnostics module for monitoring communication signals automated commissioning and troubleshooting of the fieldbus physical layer
HD2-DM-B Pepperl+Fuchs diagnostic module monitors voltage on PROFIBUS PA segments and outputs a collective fault signal
HD2-FBPS-1500 Pepperl+Fuchs modules for power hub motherboard providing 500 mA per PROFIBUS PA segment
HD2-FBPS-125360 Pepperl+Fuchs modules for power hub motherboard providing 360 mA per PROFIBUS PA segment
HD2-GTR-4PA Pepperl+Fuchs PROFIBUS DPPA gateway 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
SP-JB-Nx-xx Pepperl+Fuchs segment protector enclosures Various housing and connections available
F2D0-FB-EX4 Pepperl+Fuchs field-mounted intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
RD0-FB-Ex4 Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier Div 2Zone1 mountable with Div 1Zone 0 outputs
Configuration software HSNetworxPA software HIPROM software for configuring PROFIBUS PA devices
PROFIBUS PA Products
Category Product Description
Publication PROCES-SG001B-EN-P - September 2009 35
PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
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PlantPAx Field Device Integration and Asset Management Chapter 3
Additional Resources
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
Resource Description
httpwwwrockwellautomationcomencompass Encompass Program product directories
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
Computer Requirements - Asset Management Server
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup
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
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
36 Publication PROCES-SG001B-EN-P - September 2009
Chapter 3 PlantPAx Field Device Integration and Asset Management
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
Asset Management Products
Category Product Description
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
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
37Publication PROCES-SG001B-EN-P - September 2009 37
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
Application ServerBatch
Management
Application Server
Material Management
Topic Page
Basic Batch and Sequencing 39
Comprehensive Batch and Sequencing 41
Material Management 44
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
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PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
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PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
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Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
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Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
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Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
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Chapter 6 PlantPAx Plantwide Optimization
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
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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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
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Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
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Chapter 8
PlantPAx Infrastructure
Introduction The PlantPAx system infrastructure is built on open industry standards to support seamless integration of the system components as well as to provide connectivity to higher-level business systems In addition the PlantPAx system leverages best-of-breed technology partners where it makes 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
Attribute Requirement
Hardware bull Pentium processor
bull 20 GHz CPU
bull 1 GB memory
Software bull Windows 2003 server
bull No application software
Configuration bull Hyper-threading optional
bull DHCP enabled with IP address reservation
bull Active directory
bull Kerberos authentication protocol
bull DNS server
bull WINS server
bull No routing
bull No firewall
bull No power management
bull No screen saver
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Chapter 8 PlantPAx Infrastructure
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)
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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
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Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
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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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
38 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
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PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
-
- Introduction
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 39
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
Intrinsically Safe Area
ControlNet Links
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
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Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
-
- Introduction
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
40 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant 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
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 41
PlantPAx Batch Management and Control Chapter 4
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
Category Product Description
Process controllers ControlLogix 1756-L63 controllersbull Firmware revision 170 nonredundant
controller
bull Firmware revision 168 redundant controller
Controller-based sequencing relies on the core capabilities of the Logix controller including PhaseManager software Logix application and standard faceplates
Control logic Logix Batch and Sequence Manager software (Process object with PhaseManager interface)
Pre-developed Logix application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
Visualization Logix Batch and Sequence Manager software (Process object with FactoryTalk View screens)
Pre-developed View application add-in that enables configurable formulas (setpoints) procedures (sequences) and shared resources
Available as a process object application
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
42 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Generally these solutions are optimized for flexible sequences flexible formulation multiple unit and networked pathway coordination
There are options depending on system size and batch server location
Redundant Controller Pair
Distributed IO Racks
FOUNDATION Fieldbus Links
Intrinsically Safe Area
ControlNet Links
OWSEWS Batch Server
ControlLogix Chassis with 56SAM-838 Module
Application Server Batch Management
or
Option Description
Chassis-based server The chassis-based server offers comprehensive batch management capability from a module in the local ControlLogix chassis for smaller systems
The chassis-based batch server is the Logix 56SAM-838 specialty module from Online Development Inc The 56SAM-838 module is an in-chassis Windows-based server on which you install batch server software
Application server The application-server offers comprehensive batch management capability on a standard application server and can be scaled to meet size and performance requirements
The application batch server is a Windows-based server on which you install batch server software
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 43
PlantPAx Batch Management and Control Chapter 4
You might also need abull material management serverbull information management server
Computer Requirements - Batch Server
Attribute Requirement
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
bull Dedicated Ethernet card
bull UPS power backup recommended
Software - Batch Server
Software Product
Operating system bull Windows 2003 Server operating system
Batch software bull FactoryTalk Batch server software
bull FactoryTalk Batch Equipment Editor software
bull FactoryTalk Batch Recipe Editor software
bull FactoryTalk Batch Client software
bull FactoryTalk Batch Archiver software
Infrastructure software bull FactoryTalk Services Platform client
bull RSLinx Classic software
bull FactoryTalk Activation client software
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
44 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 45
PlantPAx Batch Management and Control Chapter 4
Software - Material Management Server
Software Product
Operating system bull Windows 2003 Server operating system
Material management software bull FactoryTalk Batch MaterialManager server software
Supported third-party software bull Symantec Antivirus software
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
46 Publication PROCES-SG001B-EN-P - September 2009
Chapter 4 PlantPAx Batch Management and Control
Notes
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
47Publication PROCES-SG001B-EN-P - September 2009 47
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
In
Channel A
Channel B
REDUNDANTCOAX BARRIER
Operator Workstation
(OWS)
Process Automation System Server
(PASS)Domain Controller
Engineering Workstation
(EWS)
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
EtherNetIP Network
Application ServerBatch
Management
Application Server
Material Management
Application Server Information Management
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
48 Publication PROCES-SG001B-EN-P - September 2009
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
Category Product Description
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
Attribute Requirement
Computer hardware bull Pentium 4 processor or better
bull 30 GHz CPU
bull 2 GB memory
bull Dedicated Ethernet card
bull UPS power backup recommended
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 49
PlantPAx Process Information Chapter 5
Software - Historical Data Server
Software Product
Operating system bull Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service)
Data management software bull FactoryTalk Historian server software
Decision support software bull FactoryTalk VantagePoint software
Infrastructure software bull FactoryTalk Services Platform server software
bull FactoryTalk View Administration Console software
bull RSLinx Classic software
bull FactoryTalk Activation server software
Optional software bull Microsoft Office 200x software
bull Microsoft reporting services
bull Antivirus software
bull Diskeeper software
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
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
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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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
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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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
50 Publication PROCES-SG001B-EN-P - September 2009
Chapter 5 PlantPAx Process Information
Notes
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
51Publication PROCES-SG001B-EN-P - September 2009 51
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
2533
3950
6470
92
115
66 1100 13
25253333
39395050
646470
9292
115
SoftSensors
ControllerMetrics
Console
SCADAHMIServices
ControlSystems
MESSystems
CustomDatabase
PlantHistorians
SPCSQCSystems
LaboratorySystems
MaintenanceSystems
Dynamic MPC
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
52 Publication PROCES-SG001B-EN-P - September 2009
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
Attribute Requirement
Client hardware bull Pentium III processor
bull 500 MHz CPU
bull 025 GB memory
bull 05 GB disk space
Application server hardware bull Pentium 4 processor
bull 24 GHz CPU
bull 24 GB memory
bull 40 GB disk space
Control application hardware bull Pentium III processor
bull 500 MHz CPU
bull 1 GB memory
bull 40 GB disk space
Software - 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
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
53Publication PROCES-SG001B-EN-P - September 2009 53
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
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
54 Publication PROCES-SG001B-EN-P - September 2009
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)
where
MTBF = Mean Time Between Failure
MDT = Mean Down Time
High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device will perform its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired
Redundant ControlLogix Controllers
Redundant Network Media
Redundant Servers Redundant Workstations
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PlantPAx Critical Process Control and Safety Systems Chapter 7
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
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PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 55
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
Ethernet interface (supervisory network) bull 1756-EN2T 1756-EN2F
bull 1756-ENBT
ControlNet interface (peer-to-peer network) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
IO interface (downlink) bull 1756-CN2 1756-CN2R
bull 1756-CNB 1756-CNBR
Severs and workstations Redundant process automation system server (PASS)
Redundant operator workstations (OWS)bull Redundant FactoryTalk View SE with automatic switchover
bull FactoryTalk Live Data services
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
56 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Fault Tolerant Configuration
Plantwide Ethernet or Serial Network
For SIL applications a programming terminal is not normally connected
Overall Safety Loop
Primary Chassis
Secondary Chassis
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
SIL-2 certified ControlLogix components are within the overall safety loopRemote IO Chassis A
Remote IO Chassis B
ControlNet or EtherNetIP Network
1492 Termination Board
Sensor
Actuator
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 57
PlantPAx Critical Process Control and Safety Systems Chapter 7
Fail Safe Configuration
SIL Rated Instruments
Premier integration between ControlLogix systems and these Endress+Hauser instruments includes integration documents Add-On Instructions and faceplates
For SIL applications a programming terminal is not normally connected
SIL-2 certified ControlLogix components are within the overall safety loopSensor
Actuator
Plantwide Ethernet or Serial Network
Overall Safety Loop
ControlNet or EtherNetIP Network
Connect to other safety-related ControlLogix and other remote IO chassis
ControlNet or EtherNetIP Network
Connect to non-safety related systems outside the ControlLogix portion of the SIL-2 certified loop
This workstation is for diagnostics and visualization(read-only access to controllers in the safety loop)
SIL Rated Instruments
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
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
58 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Additional Resources
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
Resource Description
ControlLogix Selection Guide publication 1756-SG001 ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
httpwwwrockwellautomationcomproductscertification Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications
httpwwwendresscomehproductDBshomeDBsenhomensfcontentview13f258828d9b3eecc1256f690036d98e
Complete list of SIL rated instruments from Endress+Hauser
AADvance Safety Control System
IsaGraph Development Workstation
Trusted TMR Control System
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 59
PlantPAx Critical Process Control and Safety Systems Chapter 7
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
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
60 Publication PROCES-SG001B-EN-P - September 2009
Chapter 7 PlantPAx Critical Process Control and Safety Systems
Notes
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
61Publication PROCES-SG001B-EN-P - September 2009 61
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
Attribute Requirement
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
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
62 Publication PROCES-SG001B-EN-P - September 2009
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)
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 63
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
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
64 Publication PROCES-SG001B-EN-P - September 2009
Chapter 8 PlantPAx Infrastructure
Notes
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
65Publication PROCES-SG001B-EN-P - September 2009 65
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
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
66 Publication PROCES-SG001B-EN-P - September 2009
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
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 67
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
Available Migration Tools
System Function Tool
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
68 Publication PROCES-SG001B-EN-P - September 2009
Chapter 9 PlantPAx Migration Tools
Additional Resources
Resource Description
httpwwwrockwellautomationcomsolutionsprocess
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities From the left-hand menu on the home page select DCS Migration Solutions for information on the DCS migration program
httpwwwmigratemyprocessnet Prerecorded webinars on the DCS migration program and capabilities for process customers
bull Rockwell Automation Systems Solutions Business (also known as the Manufacturing Process Solutions (MPS) group)
bull Rockwell Automation partner
bull Rockwell Automation TechSupport
DCS migration planning and project support Through project experience and recent acquisitions Rockwell Automation has extensive expertise and experience with legacy DCS and PLC migrations
radcsmigrationsrarockwellcom Email the Rockwell Automation DCS migration program
httpwwwrockwellautomationcomsolutionsprocessintegrationdocshtml
Integration documents
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
69Publication PROCES-SG001B-EN-P - September 2009 69
Notes
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
70 Publication PROCES-SG001B-EN-P - September 2009
Notes
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 71
Notes
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
-
- Process System Elements
-
- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
-
- 2 - PlantPAx Core System
-
- Introduction
- Core Control Hardware
-
- Additional Resources
-
- Core Servers and Workstations
-
- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
-
- Engineering Tools
-
- 3 - PlantPAx Field Device Integration and Asset Management
-
- Introduction
- EtherNetIP Devices
-
- Additional Resources
-
- ControlNet Devices
-
- Additional Resources
-
- DeviceNet Devices
-
- Additional Resources
-
- HART Devices
-
- Additional Resources
-
- FOUNDATION Fieldbus Devices
-
- Additional Resources
-
- PROFIBUS PA Devices
-
- Additional Resources
-
- Asset Management
-
- Asset Management Server
- Asset Management Products
-
- 4 - PlantPAx Batch Management and Control
-
- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
-
- Material Management Server
-
- 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
- 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
-
- 8 - PlantPAx Infrastructure
-
- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
-
- 9 - PlantPAx Migration Tools
-
- Introduction
- Migration Tools
-
- Additional Resources
-
- Back Cover
-
Publication PROCES-SG001B-EN-P - September 2009 73Supersedes Publication PROCES-SG001A-EN-P - March 2009 Copyright copy 2009 Rockwell Automation Inc All rights reserved Printed in the USA
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products At 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
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- PROCES-SG001B-EN-P PlantPAx Process Automation System Selection Guide
- Important User Information
- Table of Contents
- 1 - PlantPAx Process Automation System Overview
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- Introduction
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- Process System Elements
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- Architecture Classes
- Independent Class Architecture Example
- Centralized Class Architecture Example
- Distributed Class Architecture Example
- Recommended Architecture Sizes
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- 2 - PlantPAx Core System
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- Introduction
- Core Control Hardware
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- Additional Resources
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- Core Servers and Workstations
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- Process Automation System Server (PASS)
- Engineering Workstation (EWS)
- Operator Workstation (OWS)
- Independent Workstation
- Predefined Servers and Workstations
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- Engineering Tools
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- 3 - PlantPAx Field Device Integration and Asset Management
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- Introduction
- EtherNetIP Devices
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- Additional Resources
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- ControlNet Devices
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- Additional Resources
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- DeviceNet Devices
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- Additional Resources
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- HART Devices
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- Additional Resources
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- FOUNDATION Fieldbus Devices
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- Additional Resources
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- PROFIBUS PA Devices
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- Additional Resources
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- Asset Management
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- Asset Management Server
- Asset Management Products
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- 4 - PlantPAx Batch Management and Control
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- Introduction
- Basic Batch and Sequencing
- Comprehensive Batch and Sequencing
- Material Management
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- Material Management Server
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- 5 - PlantPAx Process Information
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- Introduction
- Information Management
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- 6 - PlantPAx Plantwide Optimization
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- Introduction
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- Pavilion Platform
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- 7 - PlantPAx Critical Process Control and Safety Systems
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- Introduction
- High Availability Systems
- ControlLogix SIL 1 and SIL 2 Systems
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- Fault Tolerant Configuration
- Fail Safe Configuration
- SIL Rated Instruments
- Additional Resources
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- ICS Triplex SIL 2 and SIL 3 Systems
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- 8 - PlantPAx Infrastructure
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- Introduction
- Domain Controller
- Ethernet Hardware
- System Software and Services
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- 9 - PlantPAx Migration Tools
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- Introduction
- Migration Tools
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- Additional Resources
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- Back Cover
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