Selection Guide

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

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Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING
IMPORTANT
ATTENTION
Identifies 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.
Identifies information that is critical for successful application and understanding of the product.
Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and
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Table of Contents
Chapter 1
PlantPAx Process Automation
System Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Architecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Independent Class Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 8
Centralized Class Architecture Example . . . . . . . . . . . . . . . . . . . . . . . . 10
Distributed Class Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 12
Recommended Architecture Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2
PlantPAx Core System
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Core Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Core Servers and Workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engineering Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Migration Tools and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3
PlantPAx Field Device Integration Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DeviceNet Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
and Asset Management
HART Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Foundation Fieldbus Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Profibus PA Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Asset Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 4
PlantPAx Batch Management and Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Controller-based Batch Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control
Controller-based Batch Management and Control. . . . . . . . . . . . . . . . 40

Chassis-based Batch Management and Control . . . . . . . . . . . . . . . . . . 41
Application Server Batch Management and Control . . . . . . . . . . . . . . 43
Material Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 5
PlantPAx Process Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Process Historian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Process Information and Decision Support . . . . . . . . . . . . . . . . . . . . . 48
Chapter 6
PlantPAx Plantwide Optimization
3Publication PROCES-SG001A-EN-P - March 2009
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table of Contents
Chapter 7
PlantPAx Critical Process Control Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
High Availability Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
and Safety Systems
ControlLogix SIL 1 and SIL 2 Systems. . . . . . . . . . . . . . . . . . . . . . . . . 55

ICS Triplex SIL2 and SIL 3 Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chapter 8
PlantPAx Infrastructure
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Domain Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Ethernet Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
System Software and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Publication PROCES-SG001A-EN-P - March 2009
Chapter
PlantPAx Process Automation System

Overview
Introduction
The PlantPAx system represents Rockwell Automations 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, XiAn Hengsheng and ProsCon, under a common
systems and solutions umbrella to provide a scalable, open, and cost-effective
process solution.
Chapter 1
PlantPAx Process Automation System Overview
The PlantPAx system focuses on these main areas.

Focus Area
Description
Core system
The PlantPAx core system consists of:

engineering development environment.
system-wide visualization.
multi-disciplined process control.
Size the core for small, single-unit systems or scale up the core up for large, highly-distributed,
multi-area applications. Based on Integrated Architecture automation products, the core system can
be extended through the addition of optional functions such as batch, historian, or asset
management, while providing the capability to meet critical process control, availability, and safety
requirements.
Field device integration and

asset management
In addition to supporting the most extensive range of I/O products in the industry, the core system
provides integration to:
field devices such as HART, Foundation Fieldbus, and Profibus PA devices for process
instrumentation.
DeviceNet and EtherNet/IP industrial control devices.
These interfaces provide in-depth integration when used with our device integration tools developed
through our partnership with Endress+Hauser for process instrumentation and drives and motor
controls from Rockwell Automation. Asset management capabilities include controller code change
management, vibration monitoring of rotating equipment and both instrument and industrial device
management with configuration and calibration records tracking.
Batch management and control
The PlantPAx system enables flexible production, equipment-independent recipe management,

batch-independent equipment control, and support for regulatory compliance. Operation functions
provide batch visualization, analysis, and web-based reporting. These solutions are scalable and
leverage industry standards to meet small, basic batch and sequencing needs, as well as distributed,
comprehensive batch and sequencing needs.
Process information
An integrated set of decision-making tools and dashboards provide real-time access to and analysis
of process and production information throughout the enterprise.
Produce web-based KPI dashboards and reports.
Deliver timely information to appropriate personnel throughout manufacturing derived from
various manufacturing processes.
A distributed, historical data management strategy offers localized, chassis-based, high-speed data
collection and recording, as well as site and enterprise solutions to meet the most demanding
requirements.
Critical process control and safety

systems
The PlantPAx system supports scalable solutions that meet specific requirements for availability and
safety.
ControlLogix controllers support SIL 1 and SIL 2 requirements.
GuardLogix controllers supports SIL 3 requirements.
ICS Triplex Trusted controllers support triple modular redundancy and the scalable AADvance
controllers support SIL 1, 2, and 3 capabilities in simplex, duplex, or triplex configurations. All of
the ICS Triplex solutions are CIP-enabled and part of the Rockwell Automation Integrated
Architecture.
Plantwide optimization
The PlantPAx system integrates with Pavilion8 software support model predictive control,
environmental performance management, and production performance management.
Infrastructure
Infrastructure components are built on open industry standards, support the entire PlantPAx system,
and provide connectivity to higher level business systems.
Chapter 1
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.
Architecture Classes
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.
Independent system architecture for unit control
Centralized system architecture for area control
Distributed system architecture for plant-wide and enterprise operations
Distributed
Centralized
Independent
Single Server/
Single Client
Single Server/
Multiple Cliente
Multiple Servers/
Multiple Clients
Chapter 1
Independent Class
Architecture Example
The independent class architecture is for simpler process control

configurations. The independent class architecture has field devices and
supports process control and batch functions. The independent class
architecture has limited supervisory functions in that it uses only one
workstation (the independent workstation) onto which all the software is
loaded. You can expand the independent system to include site manufacturing
operations, as needed.
An independent class architecture consists of these system elements:
One independent workstation. This single personal computer combines
software to function as a:
process automation system server (PASS).
engineering workstation (EWS) to configure and maintain the
system.
operator workstation (OWS) for the interactive graphical interface by
using custom graphics, faceplates, alarms, data logging, and trends.
Maximum of five process controllers with 125 complex regulatory
control strategies (loops) per controller, with a system maximum of 375
control strategies.
64 I/O modules per controller on an unscheduled, remote I/O
ControlNet network.
I/O components that are any I/O type and nominally 1024 points per
controller, with this distribution:
250 analog inputs (4...20 mA or HART devices)
125 analog outputs (4...20 mA or HART devices)
400 digital inputs
200 digital outputs
4 specialty modules (such as Foundation Fieldbus linking devices,
Profibus PA bridges, or DeviceNet bridges)
Chapter 1
This diagram shows an example process control system based on the

independent class architecture.
Chapter 1
Centralized Class
Add workstations with dedicated roles to expand the independent class

architecture to a centralized class. Use a centralized class architecture for
applications with multiple process units that cover a large physical area and
that require multiple OWS. A centralized system adds capabilities such as
advanced data collection (historian), complex batch control and management,
and basic MES interconnectivity.
The centralized system is a multi-client configuration that supports the
automating a single production or process area. The system elements can
provide main control room operation and enable you to mount operator
workstations locally throughout the production facility. The centralized system
expands the independent system by adding:
dedicated process automation system server (PASS) as the central HMI
server (optionally a redundant pair of servers).
dedicated engineering workstation (EWS) for the development and
maintenance of the full system, including system security.
multiple operator workstations (OWS) for the interactive graphical
interface.
application servers for batch management, data acquisition (historian),
or change management (asset management).
A centralized system supports these system elements:
One PASS.
As many as eight OWS.
Maximum of six process controllers with 125 complex regulatory
control strategies (loops) per controller, with a system maximum of 500
control strategies.
64 I/O modules per controller on an unscheduled, remote I/O
ControlNet network.
400 digital inputs
200 digital outputs
10
Chapter 1

centralized class architecture.
11
Chapter 1
Distributed Class
The distributed class architecture expands on the centralized class by adding

application servers to interconnect multiple process areas into a system. The
distributed system is a multi-server, multi-client configuration that supports
automating a process with semi-independent areas. The system elements
provide main control room operation and enable you to mount OWS locally
throughout the production facility. The distributed system supports:
dedicated process automation system server (PASS) as the central HMI
server.
dedicated engineering workstation (EWS) for the development and
maintenance of the full system, including system security.
multiple operator workstations (OWS) for the interactive graphical
interface.
application servers for batch management, data acquisition (historian),
or change management (asset management).
Use a distributed system for applications that require independent, but
connected, control areas. Typical distributed systems include independently
operated production lines. A distributed system can have up to four control
areas. Each of these four control area supports these elements:
One PASS (optionally a redundant pair of servers).
As many as 32 OWS.
One central EWS.
Maximum of 24 process controllers with 125 complex regulatory
control strategies (loops) per controller, with a system maximum of
2000 control strategies.
64 I/O modules per controller on a unscheduled, remote I/O
ControlNet network.
400 digital inputs
200 digital outputs
12
Chapter 1

distributed class architecture.
13
Chapter 1
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:
PASS
None
None
EWS
OWS
EWS
PASS
Included in independent
workstation
workstation
HMI supports these on scan:
1000 display points
1000 alarms with Acks per
controller
50 data log points logged per
second per controller
Application servers
None
One EWS required
One EWS required
Can have as many as 5 EWS
Can have as many as 5 EWS
One PASS required and includes:

FactoryTalk Directory server
One PASS required and includes:

FactoryTalk Directory server
HMI server
HMI server
Data server
Data server
PASS supports:
1000 display points per OWS
PASS supports:

controller

controller


One batch server
One batch server

Three AppSer-HMI, each with:
controller
OWS
workstation
8 remote clients
8 remote clients for PASS

8 additional remote clients per
AppSer-HMI
Domain controller
Optional
Required
Required
Process controller
1...5 ControlLogix controllers

125 control strategies (complex
analog loops) per controller at a
250 ms period
1...6 ControlLogix controllers

250 ms period
375 total control strategies per

system

system
1...6 ControlLogix controllers per

PASS
1...6 ControlLogix controllers per
AppSer-HMI
250 ms period
system
14
Chapter
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
I/O modules, linking devices and bridges, as well as the network
infrastructure.
Section
Page
Core Control Hardware
16
Core Servers and Workstations
17
Engineering Tools
20
Migration Tools and Services
21
15
Chapter 2
Core Control Hardware
The core control components come from the ControlLogix family of

products. The ControlLogix controller is the process controller and also
provides process, sequential, discrete, and drive control. Separate modules
provide connectivity to system networks, field devices, and third-party
products.
Control Hardware
Hardware
Product
Process controller
ControlLogix 1756-L63 controllers

Firmware revision 16.0, non-redundant controller
Firmware revision 16.5, redundant controller
I/O modules
Redundancy modules
1756 discrete, analog, and specialty

1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)
1757-SRM
Ethernet interface (supervisory network)
1756-EN2T, 1756-EN2F
1756-ENBT
1756-EWEB
ControlNet interface (peer-to-peer network)
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
I/O interface (downlink)
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
Display devices
1700 Integrated display computer
Additional Resources
Resource
Description
ControlLogix Selection Guide, publication 1756-SG001
ControlLogix system components.
NetLinx Selection Guide, publication NETS-SG001
EtherNet/IP, ControlNet, and DeviceNet network components.
Visualization Platforms Selection Guide, publication VIEW-SG001
Operator interface terminals, industrial computers and monitors,

HMI software, and message display components.
16
Chapter 2
The PlantPAx system uses these core servers and workstations:

Process automation system server (PASS)
Engineering workstation (EWS)
Operator workstation (OWS)
Core Servers and

Workstations
Computer Requirements - Workstations and Servers

Attribute
PASS and EWS
Computer hardware
OWS
Pentium 4 dual core processor
Pentium 4 processor
3.0 GHz CPU
2.0 GHz CPU
2 GB memory
512 MB memory
ATI video card
ATI video card
Dedicated Ethernet card
UPS power backup recommended
Server Software - PASS

The process automation system server (PASS) is the process system server.
The PASS can also provide HMI, data, and OPC server functions.
Software
Product
Operating system
Windows 2003 Server operating system
Visualization software
FactoryTalk View SE server software

FactoryTalk View SE client software
FactoryTalk View Studio software(1)
Infrastructure software
FactoryTalk Services Platform server software

FactoryTalk View Administration Console software
FactoryTalk Historian Live Data Interface software
RSLinx Enterprise software
RSLinx Classic software
Logix5000 Clock Tool software
FactoryTalk Activation server software
Supported third party software
Norton/Symantec Antivirus software

Diskeeper software
Norton/Symantec Ghost software
Microsoft Internet Explorer 6 software
Microsoft Internet IIS with WWW service (required)
Optional software
FactoryTalk View server upgrade

SCADA interface software
(1)
Required only for initial set up. Take advantage of concurrent licensing with an EWS.
17
Chapter 2
Workstation Software - EWS

The engineering workstation (EWS) supports system configuration,
application development, and maintenance functions. This is the central
location for monitoring and maintaining the systems operation.
Software
Product
Operating system
Windows XP Professional operating system
Control development software
RSLogix 5000 Professional Edition software

RSLogix Architect software(1)
RSLogix Emulate 5000 software(1)
Fuzzy Designer software (optional)
Visualization development software

FactoryTalk View Studio software
Batch development software
FactoryTalk Batch Equipment Editor software

FactoryTalk Batch Simulator software
FactoryTalk Batch Recipe Editor software
FactoryTalk Batch View client software
FactoryTalk Batch MaterialManager software
Asset management development software
FactoryTalk AssetCentre client software

FactoryTalk AssetCentre audit support(1)
Process information development software
FactoryTalk Historian Process Book software (optional)

FactoryTalk Historian Datalink software (optional)
FactoryTalk Historian Batch View software (optional)
FactoryTalk Historian SPC software (optional)
Windows .NET Framework 2.0 software

FactoryTalk Services Platform client software
FactoryTalk View Administration Console software
FactoryTalk Historian Datalink software
RSLinx Enterprise software
RSLinx Classic software(1)
FactoryTalk Activation server
FactoryTalk security server software(1)
18
Software
Chapter 2
Product
Adobe Acrobat Reader 8.0 software
Diskeeper software
Microsoft Internet Explorer 7 software for FactoryTalk VantagePoint EMI
Microsoft Internet IIS with WWW service
Microsoft Office 2007 software
Configuration software (optional)
IntelliCENTER software for motor control centers

RSFieldbus software for Foundation Fieldbus devices
HIPROM HSNetworxPA software for Profibus PA devices
Endress+Hauser Fieldcare software
(1)
Included with RSLogix 5000 Professional Edition software.
Workstation Software - OWS

The operator workstation (OWS) provides the graphical view and interface
into the process. The workstation is a client of either a PASS or application
HMI server. The OWS supports operator interaction and is not meant to
support development or maintenance activities.
Software
Product
Operating system
Windows XP Professional operating system
Visualization software
Batch software
FactoryTalk Batch client software
Asset management software
FactoryTalk AssetCentre client software
Process information development software
FactoryTalk Historian Process Book Client for View software

FactoryTalk Historian Trend for View software


Microsoft Office 2007 software
19
Chapter 2
Independent Workstation
The independent workstation (IndWS) is a single computer that contains all
the system software to develop, operate, and maintain an independent process
application. The IndWS integrates the functions of multiple servers (PASS and
other application servers) and workstations (EWS and OWS) into one
computer.
Attribute
Hardware
IndWS
3.0 GHz CPU
2 GB memory
ATI video card
Engineering Tools
PlantPAx technical tools for design and development include:
Category
Tool
Process system library
Rockwell Automation branded and supported library of building blocks that support
process devices (such as valve, motor, and transmitter) consisting of:
controller logic (Add-On Instructions).
graphical objects.
templates.
Application development
Logix View Utility is an engineering tool which helps you bulk generate portions of your
application based on libraries of logic and human interface components.
Create logic templates from your control logic libraries and define how to map tags
when creating instances.
Create display templates from your visualization libraries and define how to map tags
when creating instances.
20
Migration Tools and

Services
Chapter 2
Rockwell Automation provides a DCS Migration Program to assist customers

and integrators with migrating legacy DCS systems to PlantPAx systems. This
program provides tools for the migration of legacy (competitive) and
field-proven (Rockwell Automation) systems to PlantPAx systems. Rockwell
Automation works internally and with partners to develop tools and support
projects. This program also works to develop engineering competence and
capacity within Rockwell Automation and its partners for planning, executing,
and otherwise supporting DCS migration projects.
Systems that can be migrated to PlantPAx systems include:
Bailey Net90 and Infi90 control systems.
Honeywell TDC 2000, TDC 3000 and TPS systems.
Emerson (Fisher Controls) PROVOX systems.
Invensys (Foxboro) I/A systems.
For each system, there is a general migration plan that describes the particular
goals and methods for system migration, as well as specifics on the tools
currently available for migrating that system.
Other target systems include Rockwell Automation ProcessLogix, Emerson
(Westinghouse) WDPF, Siemens (Moore) APACS, and other systems.
Migration Tools
Tools can reduce engineering effort and risk during system migration, even
though additional engineering support may be required. Migration tools
preserve the engineering investment in existing control systems. A
combination of tools and other activities extract and document existing
applications of a legacy DCS system and convert them into appropriate
applications within a PlantPAx system.
The functional location where a particular function was performed in a legacy
system may be different from the level and functional area in PlantPAx. Also,
there may be improvements in application design and implementation which
have resulted from efforts in developing engineering standards for automation
and control applications.
Legacy systems differ from PlantPAx in their general architecture and
approach to control systems
As control systems technology has advanced, increased intelligence has
been driven downward in the plant information infrastructure.
21
Chapter 2
The following table presents a description of tools available for legacy DCS
migration support. Not all tools are available for each target legacy DCS
system.
Category
Business systems integration
Function
System-to-system, direct connections
Transactional connections
Direct database connections
Tools
Typically, today, these connections are replaced
with a transaction brokering structure and are not
replaced in kind.
Use advanced functionality for transaction brokering.
Update with more current database
interconnectivity, such as with Microsoft database
interconnection tools.
Production management
Historical data collection

Batch management
There are migration tools for targeted historical

databases of DCS systems and older plant and
process historians
Batch systems may have a mechanism to export
batch recipes. Recipes may require hand-mapping
into target batch management application.
Operator consoles (supervisory

control and operations)
Console level interconnection between

systems
Console tag database
Alarms and events
Standard displays
Custom graphics displays
Generally, there is a defined mechanism for

connecting and sharing information at the console
level, often via OPC technology.
Export or extract console tags from the legacy
system or console subsystem and autogenerate a
tag database for the PlantPAx system.
Establish alarms and events at the console level of
the PlantPAx system or migrate to controller-based
tags.
Faceplates may be available to maintain the
look-and-feel of the legacy DCS.
Conversion utilities may be available to convert all or
part of the legacy DCS operator graphics displays.
Control Networks
Controller-to-controller communications
Control layer-to-control layer
communications
The PlantPAx system supports standard interfaces for

direct data communication, like Modbus, ControlNet,
EtherNet/IP networks.
Tools may be available to allow functional
interconnection between systems at the control layer.
22
Category
Controllers
Function
Chapter 2
Tools
Control applications
Modular control applications
Tools are available to convert some legacy control

system control application structures to PlantPAx
structures.
Where possible, leverage the PlantPAx process
engineering libraries for their use of PlantPAx features.
I/O
I/O connectivity
Smart Instruments
Cables to I/O Terminations
I/O Field Termination Units
There are I/O scanner modules for some legacy DCS

I/O subsystems. I/O scanners communicate from
PlantPAx communication modules to I/O networks
formerly connected to legacy DCS controllers.
Legacy DCS systems may have made use of HART
protocol. Strong support for smart instrument and
control device networks is available in standard
PlantPAx functions.
New cables connect legacy DCS field termination
wiring to PlantPAx I/O processing modules
Resource
Description
http://www.rockwellautomation.com/solutions/process
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.
Or contact your local Rockwell Automation representative.

http://www.migratemyprocess.net
Rockwell Automation Systems Solutions Business (also
known as the Manufacturing Process Solutions (MPS)
group)
Prerecorded webinars on the DCS migration program and capabilities for

process customers.
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.
Rockwell Automation partner

Rockwell Automation TechSupport
radcsmigrations@ra.rockwell.com
Email the Rockwell Automation DCS migration program.
23
Chapter 2
Notes:
24
Chapter
PlantPAx Field Device Integration and

Asset Management
Introduction
Field device components include interfaces, instruments, actuators, drives, and

field devices. These components include DeviceNet, HART, Foundation
Fieldbus, and Profibus PA devices.
Section
Page
DeviceNet Devices
26
HART Devices
28
Foundation Fieldbus Devices
30
Profibus PA Devices
32
Asset Management
35
25
Chapter 3
PlantPAx Field Device Integration and Asset Management
The DeviceNet network is an open low-level network that provides

connections between simple industrial devices (such as sensors and actuators)
and higher-level devices (such as PLC controllers and computers). The
DeviceNet network uses the proven Common Industrial Protocol (CIP) to
provide the control, configure, and data collection capabilities for industrial
devices.
DeviceNet Devices
EtherNet/IP
ControlLogix
DeviceNet
Sensor
Push Buttons
1734 I/O
CENTERLINE
DeviceNet Products
Category
Product
Description
ControlLogix controller interface
1756-DNB
Operates as ControlLogix DeviceNet scanner.
In-cabinet I/O modules
1734 POINT I/O
Use one of these adapters:

1734D POINTBlock series, interface with integrated I/O.
1734-ADN adapter.
1734-ADNX adapter with subnet connectiv.ity.
1734-PDN communication interface
26
1790 CompactBlock LDX I/O
Built-in adapter in base block.
1791D CompactBlock I/O
Built-in adapter in base block; DeviceLogix Smart Component

Technology.
1794 FLEX I/O
1794-ADN adapter.
1797 FLEX Ex intrinsically safe I/O
1794-ADN adapter (use with 1797-BIC and 1797-CEC to connect

to hazardous areas).
Category
Product
Description
On-machine I/O modules
1732 ArmorBlock I/O
Built-in adapter in base block.
1738 ArmorPoint I/O
Use one of these adapters:

1738-ADN12 adapter with M12 Quick-Disconnect
terminations.
Chapter 3
1738-ADN18 adapter with mini connector (drop).

1738-ADN18P adapter with mini connector (pass-thru).
1738-ADNX adapter with subnet connectivity.
1792 ArmorBlock MaXum I/O
Built-in adapter in base block; DeviceLogix Smart Component

Technology.
1799 Embedded I/O
Built-in adapter; DeviceLogix Smart Component Technology.
1756 ControlLogix I/O
1756-DNB module.
1762 MicroLogix expansion I/O
1761-NET-DNI linking device.
1769 Compact I/O
1769-ADN adapter.
1771 PLC-5 I/O
1771-SDN module.
XM condition monitoring
specialty modules
1440 Emonitor Modules
Built-in adapter.
Motor control centers
2100 CENTERLINE Motor Control

Centers
Built-in adapter.
Chassis-based I/O modules
Resource
Description
NetLinx Selection Guide, publication NETS-SG001
EtherNet/IP, ControlNet, and DeviceNet network components.
POINT I/O Selection Guide, publication 1734-SG001
1734 POINT I/O modules.
FLEX I/O and FLEX Ex I/O Selection Guide, publication 1794-SG002
1794 FLEX and 1797 FLEX Ex I/O modules
ArmorBlock MaXum I/O and ArmorBlock I/O Selection Guide,

publication 1792-SG001
1732 ArmorBlock and 1792 ArmorBlock I/O modules.
ArmorPoint I/O Selection Guide, publication 1738-SG001
1738 ArmorPoint I/O module.
Embedded I/O For DeviceNet Technical Data, publication

1799-TD001
1799 Embedded I/O products.
http://www.rockwellautomation.com/encompass
Encompass Program product directories
27
Chapter 3
Highway Addressable Remote Transmitter (HART) is an open protocol

designed to connect analog devices. For HART connectivity, select from
products available from Rockwell Automation and our Encompass partners.
HART Devices
EtherNet/IP
ControlLogix
ControlNet or EtherNet/IP
FLEX I/O
HART Products
Category
Product
Description
Chassis-based I/O modules
1756-IF8H
1756-OF8H
ControlLogix analog I/O modules with:

standard profiles in RSLogix 5000 software.
DTMs.
Distributed I/O modules
MVI56-HART
Prosoft ControlLogix I/O module.
1794-IE8H
1794-OE8H
1794-IF8IH
1794-OF8IH
FLEX and FLEX Ex analog I/O modules with:

standard profiles in RSLogix 5000 software.
DTMs.
1797-IE8H
1797-OE8H
1769-sc-IF4IH
1769-sc-OF4IH
28
Spectrum Compact I/O modules.
Category
Product
Description
Multiplexers/gateways
FPIO-I8H-EIP FieldPort device
Spectrum gateways.
Chapter 3
FPIO-O8H-EIP FieldPort device

2700 HART Multiplexer
Pepperl+Fuchs HART multiplexer; requires a multiplexer

termination panel, such as HPSM/32/MM-01.
5100 serial gateways
ProSoft gateways.
6000 wireless gateways

Handheld devices
SFX100 Field Xpert handheld device
Endress+Hauser product.
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:
pre-engineered controller code with Add-On Instructions that provide
two-way exchange of data between faceplates and the ControlLogix
controller.
pre-configured operator faceplates that provide visualization of
instruments connected to the network interface.
integration documentation that describes the implementation.
Resource
Description
FLEX I/O and FLEX Ex I/O Selection Guide, publication 1794-SG002
1794 FLEX and 1797 FLEX Ex I/O modules
http://www.rockwellautomation.com/solutions/process/integratio
ndocs.html
Integration documents
Add-On Instructions and Faceplates for Visualizing HART Instrument How to implement the HART Add-On-Instruction in controller logic
Data in FactoryTalk View SE, Knowledgebase document (Login
to work with the FactoryTalk View faceplates for HART instruments.
required. Please contact your sales representative.)
http://rockwellautomation.custhelp.com/cgi-bin/rockwellautomatio
n.cfg/php/enduser/std_adp.php?p_faqid=54857
29
Chapter 3
Foundation Fieldbus is a communication network created by the Fieldbus

Foundation. It is a protocol designed for robust, distributed control of process
control applications. Devices connected by a Foundation Fieldbus network
can be used for sophisticated, highly distributed process control.
Foundation Fieldbus
Devices
EtherNet/IP
ControlLogix
ControlNet
EtherNet/IP
1757-FFLDC
1757-FFLD
Foundation Fieldbus Products

Category
Product
Description
EtherNet/IP interface
1757FFLD2
1757-FFLD4
Bridge from an Ethernet network to either two or four H1 ports.
ControlNet interface
1757-FFLDC2
1757-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-Ex4.FF
Pepperl+Fuchs discrete I/O module: 4 outputs; 8 inputs;

intrinsically safe.
DP-LBF-I1.34
Pepperl+Fuchs surge protection modules compatible with IEC

61158-2. DIN-rail mountable base and removable module.
FN-FT-Ex1.D.IEC
Pepperl+Fuchs Foundation Fieldbus H1 intrinsically-safe

terminator, which screws into a 1/2 in. NPT transmitter port.
30
Chapter 3
Category
Product
Description
Power conditioning products
KLD2-FBPS-1.25.360
Pepperl+Fuchs Foundation Fieldbus 360 mA, 25...27 V DC

isolated power supply, DIN rail.
HD2-FBPS-1.500
Pepperl+Fuchs modules for power hub motherboard providing

500 mA per Foundation Fieldbus H1 segment.
HD2-FBPS-1.25.360

360 mA per Foundation Fieldbus H1 segment.
MB-FB-x
Pepperl+Fuchs power hub motherboard available in:

1R one redundant segment.
2R two redundant segments.
4 four segments.
4R four redundant segments.
Segment protection
Configuration software
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.
R2-SP-Nx
Pepperl+Fuchs segment protector provides current limiting

nonincendive energy to Foundation Fieldbus H1. Mount inside
cabinet. Terminals for 4,6 8,10, and 12 spurs.
SP-JB-Nx-x.x
Pepperl+Fuchs segment protector enclosures. Various housing

and connections available.
F2D0-FB-EX4
Pepperl+Fuchs field-mounted intrinsic safety barrier,

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

RSFieldbus software
Configure Foundation Fieldbus devices.
Foundation Fieldbus offers the ability for devices to share information among
each other. Control in the field is possible on same segment, and the segment
will continue to run even without the control system. Field device data can also
be accessed via an OPC server. Device integration tools provide access to
isolated diagnostics and step-by-step guidance on connectivity, configuration,
and commissioning of Endress+Hauser Foundation Fieldbus field devices
with the PlantPAx system. These tools include:
controller.
31
Chapter 3
Resource
Description
ndocs.html
The Profibus (Process Field Bus) PA (Process Automation) network is the

Profibus solution for process automation. Profibus PA connects automation
systems and process control systems with field devices such as flow, level,
pressure, and temperature transmitters. Profibus PA is ideal for
explosion-hazardous areas (Ex-zone 0 and 1).
Profibus PA Devices
EtherNet/IP
ControlLogix
EtherNet/IP
32
Chapter 3
Profibus PA Products
Category
Product
Description
Profibus interface
1788HP-EN2PA
HIPROM ControlLogix EtherNet/IP to Profibus PA linking device.
Profibus network components
FD0-VC-Ex4.PA
Pepperl+Fuchs discrete I/O module: 4 outputs; 8 inputs;

intrinsically safe.
DP-LBF-I1.34
Pepperl+Fuchs surge protection modules compatible with IEC

61158-2. DIN-rail mountable base and removable module.
FN-FT-Ex1.D.IEC
Pepperl+Fuchs Profibus PA intrinsically-safe terminator, which

screws into a 1/2 in. NPT transmitter port.
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-1.500

500 mA per Profibus PA segment.
HD2-FBPS-1.25.360

360 mA per Profibus PA segment.
HD2-GTR-4PA
Pepperl+Fuchs Profibus DP/PA gateway, 4 PA segments.
MB-FB_GT
Pepperl+Fuchs motherboard for simplex gateway.
MB-FB_GTR
Pepperl+Fuchs motherboard for redundant gateway.
MB-FB-4.GEN
Pepperl+Fuchs power supply motherboard, 4 segments.
MB-FB-4R.GEN
Pepperl+Fuchs power supply motherboard, 4 redundant

segments.
KT-MB-GTR-2PA
Compact segment coupler kit - 2 PA segments -DP/PA segment

coupler and power modules and motherboard.
R2-SP-Nx
Pepperl+Fuchs segment protector provides current limiting

nonincendive energy to Profibus PA. Mount inside cabinet.
Terminals for 4,6 8,10, and 12 spurs.
SP-JB-Nx-x.x
Pepperl+Fuchs segment protector enclosures. Various housing

and connections available.
F2D0-FB-EX4
Pepperl+Fuchs field-mounted intrinsic safety barrier,

RD0-FB-Ex4
Pepperl+Fuchs DIN-rail mountable intrinsic safety barrier,

HSNetworxPA software
HIPROM software for configuring Profibus PA devices.
Power conditioning products
Segment protection
Configuration software
33
Chapter 3
Profibus PA device integration uses the EN2PA module as an Ethernet PA

master, linking directly to the PA bus and connecting PA field devices to the
ControlLogix controller. Device integration tools provide access to isolated
diagnostics and step-by-step guidance on connectivity, configuration, and
commissioning of Endress+Hauser PA field devices with the PlantPAx
system. These tools include:
controller.
Resource
Description
ndocs.html
34
Asset Management
Chapter 3
Asset management adds to the core system components the functions for
optimizing maintenance and plant operations. This includes comprehensive
diagnostics, calibration, real-time monitoring, as well as auditing equipment
and network health to improve overall resource availability.
Computer Requirements - Application Server

Attribute
Computer hardware
Application Server
3.0 GHz CPU
2 GB memory
ATI video card
Server Software - Asset Management

The asset management server provides a centralized system management for
end field devices.
Software
Product
Operating system
Asset management software
FactoryTalk AssetCentre server software

FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software
Microsoft SQL Server 2000 software
Optional software
IntelliCENTER software for motor control centers
35
Chapter 3
Notes:
36
Chapter
PlantPAx Batch Management and Control
Introduction
PlantPAx batch management solutions enable you to develop cost-effective

batch control strategies by supporting flexible production capabilities,
equipment independent recipes, and batch-independent equipment control.
Section
Page
Controller-based Batch Sequencing
39
Controller-based Batch Management and Control
40
Chassis-based Batch Management and Control
41
Application Server Batch Management and Control
43
Material Management
45
37
Chapter 4
Rockwell Automation understands there are diverse batch processing needs:

simple, single vessel, single product manufacturing to complex multi-path,
multi-vessel, multi-product manufacturing; or any combination of these. Each
need requires a different recipe and process management and control
approach.
Solution optimized for fixed sequences, fixed formulation, and simple
equipment control.
Solution optimized for fixed sequences, flexible formulation, and simple
equipment control.
Solution optimized for flexible sequences, flexible formulations,
multiple unit coordination.
Solution optimized for flexible sequences, flexible formulation, multiple
unit coordination, and networked pathway coordination.
In addition to this, batch management & control should also address other
business and production functions as well. These include:
process monitoring and control.
manufacturing operations.
business and supply chain integration.
information, analysis, and reporting.
regulation, standards, and best practices.
security, availability, and data integrity.
maintenance, support, and training.
Understanding both process complexity and business and production
functions is critical to defining the right solution to meet your demanding
requirements.
38
Chapter 4
Controller-based sequencing solutions rely on core system Logix functionality

(PhaseManager software and the sequential function chart SFC language) to
provide basic sequencing in the controller. This solution offers the capability
for small systems to adapt standards without the overhead of more complex
batch management and control functionality. PhaseManager software provides
a repeatable, code organization model. The SFC language is the fixed
sequencing mechanism.
Controller-based Batch
Sequencing
Generally these solutions are optimized for fixed sequences, fixed formulation,
and simple equipment control.
Redundant Controller Pair
Distributed I/O Racks
ControlNet Links
Foundation Fieldbus Links
Intrinsically Safe Area

Class 1, Div 1
Controller-based Batch Sequencing Products

Category
Product
Description
Process controllers

Firmware revision 16.0, non-redundant
controller
Controller-based sequencing relies on the core

capabilities of the Logix controller including
PhaseManager and SFC language
39
Chapter 4
Controller-based Batch
Management and Control
Controller-based batch management and control solutions extend the core

system Logix functionality (PhaseManager software) to provide basic batch
management and control functionality in the controller. This solution offers
the capability for small systems to adapt standards, provides local formulation
management, and enables flexible procedure definition without the overhead
of more comprehensive server/software-based solutions. PhaseManager
software is the basis for process control code. A controller-based batch engine
provides recipe management, information management, process management,
and unit supervision.
Generally these solutions are optimized for flexible sequences, flexible
formulation, and simple equipment control.
Controller-based Batch Management and Control Products

Category
Product
Description
Process controllers

controller

PhaseManager and SFC language.

Batch control logic
ControlLogix batch code extension
Available as part of the process application toolkit.
Batch visualization
FactoryTalk View batch visualization extension
Available as part of the process application toolkit.
You might also need a SQL server for reporting and logging.
40
Chapter 4
Chassis-based batch management and control solutions combine the core

system Logix functionality (PhaseManager software) with batch software
(FactoryTalk Batch software) to provide batch management and control
functionality. This solution offers the comprehensive batch management
capability packaged in a local chassis module for small systems. PhaseManager
software continues to be the basis for process control code in the controller.
FactoryTalk Batch software provides recipe management, information
management, process management, and unit supervision.
Chassis-based Batch
Generally these solutions are optimized for skid-based flexible sequences,

flexible formulation, and multiple unit coordination.
EWS
OWS
ControlNet Links

Class 1, Div 1
41
Chapter 4
Chassis-based Batch Management and Control Products

Category
Product
Description
Process controllers

controller


In-chassis batch module
1756-SAM
The Logix specialty application module is an

in-chassis, Windows-based computer on which
the FactoryTalk Batch software is installed.
Batch visualization
Available as part of the process application

toolkit.
1756-SAM Module Software - Batch

The 1756-SAM module is a Windows-based computer that resides in the
ControlLogix chassis.
Software
Product
Operating system
Batch software
FactoryTalk Batch server software

FactoryTalk Batch Client software
FactoryTalk Batch Archiver software
FactoryTalk eProcedure software (optional)

You might also need a:

material manager server.
historian server for batch analysis.
SQL server for reporting and logging.
42
Chapter 4
Application server batch management and control solutions leverage the core
system Logix functionality (PhaseManager software) in conjunction with batch
software (FactoryTalk Batch software) to provide batch management and
control functionality. This solution offers the user comprehensive batch
management capability on a standard application server and can be scaled to
meet increased requirements. PhaseManager software continues to be the basis
for process control code in the controller. FactoryTalk Batch software
provides recipe management, information management, process management,
and unit supervision.
Application Server Batch

Generally these solutions are optimized for flexible sequences, flexible

formulation, multiple unit, and networked pathway coordination.
EWS
Application Server Batch Management
OWS
ControlNet Links

Class 1, Div 1
43
Chapter 4

Attribute
Computer hardware
Application Server
3.0 GHz CPU
2 GB memory
ATI video card
Server Software - Batch

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

FactoryTalk Batch Client software
FactoryTalk Batch Archiver software
FactoryTalk eProcedure software (optional)
Process historian software
FactoryTalk Historian Batch EVT Interface software (optional)
FactoryTalk Services Platform client

FactoryTalk Activation server
You might also need a:

material manager server.
historian server for batch analysis.
SQL server for reporting and logging.
44
Chapter 4
Application Server Batch Management and Control Products

Category
Product
Description
Process controllers

controller


Batch visualization
Material Management
Available as part of the process application

toolkit.
The material management extension of batch management and control

provides an active material management and inventory system. This includes
material-based phase definitions in batch execution which enables just-in-time
material and equipment selection to provide flexible batch manufacturing and
real-time production scheduling.
Application Server Batch Management
Application Server Material Management
EtherNet/IP
Controller and Field

Device Interfaces
Link to Distributed I/O
45
Chapter 4

Attribute
Computer hardware
Application Server
3.0 GHz CPU
2 GB memory
ATI video card
Server Software - Material Manager

The material manager server integrates with company-wide inventory
management systems. The server complements ERP-level resource
management by collecting the detailed material and equipment tracking
information
Software
Product
Operating system
Material management software
FactoryTalk Batch MaterialManager server software
Microsoft SQL Server 2000 software (archival and web-based reporting)

Diskeeper software
46
Chapter
Introduction
PlantPAx process information subsystems include an integrated set of

decision-making tools and dashboards that provide real-time access to and
analysis of process and production information throughout the enterprise.
These tools:
provide process historian capability.
produce web-based KPI dashboards and reports.
deliver timely information to appropriate personnel throughout
manufacturing derived from various manufacturing processes.
Section
Page
Process Historian
48
Process Information and Decision Support
48
47
Chapter 5
Process Historian
The process historian provides collection and storage of historical contextual

data for some or all of the process information. Process historian analytic tools
can then be used to view and analyze this historical data.

Attribute
Computer hardware
Application Server
3.0 GHz CPU
2 GB memory
ATI video card
Server Software - Process Historian

The process historian server supports real-time data collection.
Software
Product
Operating system
Historian software
FactoryTalk Historian server software
FactoryTalk Services Platform server with Admin Console software

Process Information and

Decision Support
48
The PlantPAx subsystem for process information and decision support

provides access to all process and enterprise data sources and delivers timely,
web-based analyses, visualizations, and reports to process and business
stake-holders. This subsystem is comprised of FactoryTalk VantagePoint
software on an enterprise management intelligence (EMI) server, appropriate
data source connectors, and web-based thin clients. Typical data sources
include PlantPAx controllers, historians, databases (such as ORACLE and
SQL), enterprise applications (such as SAP, via R3, and Netweaver
connectors), laboratory, quality, and maintenance systems, batch and alarms
and events systems, and legacy (third-party) systems.
Chapter 5

Attribute
Computer hardware
Application Server
3.0 GHz CPU
2 GB memory
ATI video card
Server Software - Enterprise Management Intelligence

The enterprise management intelligence (EMI) server provides unified access
to manufacturing and plant data sources and supports web-based reporting.
Software
Product
Operating system
EMI software
FactoryTalk VantagePoint EMI software
FactoryTalk Services Platform server software


Diskeeper software
SQL Server 2005 software (can be remote)
Optional components
MS Office 2007 software

FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software
Concurrent or Named User client licenses
Data source connectors for databases and enterprise applications
49
Chapter 5
Notes:
50
Chapter
Introduction
Complex industrial processes make it challenging to be both market-driven

and run profitable operations. Manufacturers reformulate their production
methodology - introducing a greater variety of higher value products, more
frequent changeovers, and shorter production runs. Manufacturers find new
ways to increase their agility in order to quickly respond to changing demand
and profitably capitalize on new market opportunities.
The Pavilion8 software platform from Pavilion Technologies, a Rockwell
Automation company, is a modular software platform that includes modules to
control, analyze, monitor, visualize, warehouse, and integrate. Model Predictive
Control (MPC) technology is an intelligence layer on top of basic automation
systems that continuously drives the plant to achieve multiple business
objectives - cost reductions, decreased emissions, consistent quality, and
production increases - every production minute. MPC technology
continuously assesses current and predicted operational data, compares them
to desired results, and computes new control targets to reduce in-process
variability and improve process performance.
Console
Controller
Metrics
115
92
Soft
Sensors
64
70
50
39
33
25
10
10
13
Dynamic MPC
SCADA/HMI
Services
Control
Systems
MES
Systems
Custom
Database
Plant
Historians
SPC/SQC
Systems
Laboratory
Systems
Maintenance
Systems
51
Chapter 6
Computer Requirements - Pavilion Platform

Attribute
Client hardware
Application Server
Pentium III processor
500 MHz CPU
0.25 GB memory
0.5 GB disk space
Application server
hardware
Pentium 4 processor
2/4 GHz CPU
2/4 GB memory
40 GB disk space
Control application
hardware
Pentium III processor

500 MHz CPU
1 GB memory
40 GB disk space
Software - Pavilion Platform

The Pavilion platform supports model predictive control, environmental
performance management, and production performance management.
Software
Client
Product
Internet Explorer 6.0 software with Service Pack 1
Application sever
Windows 2000, Windows XP, or Windows 2003 Server operating system

Console Service software
Pavilion Data Access Service (PDAS) software
Control application
Windows 2000 or Windows XP operating system

Pavilion 8 Model Predictive Control software
52
Chapter
PlantPAx Critical Process Control and Safety

Systems
Introduction
The combination of Rockwell Automation and ICS Triplex, a Rockwell

Automation company, products, the PlantPAx system supports expanded
process safety offerings that provide high levels of availability and of safety and
critical process control.
Section
Page
High Availability Systems
54
ControlLogix SIL 1 and SIL 2 Systems
55
ICS Triplex SIL2 and SIL 3 Systems
58
53
Chapter 7
PlantPAx Critical Process Control and Safety Systems
High Availability Systems
Critical processes requires systems with high availability in order to:

maintain production.
protect against equipment or product losses.
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 Servers
Redundant Workstations
Redundant Network Media
Redundant ControlLogix
Controllers
54
Chapter 7
High Availability Products

Product
Description
Process controller
Redundant ControlLogix 1756-L63 controllers:

Firmware revision 16.5
Redundant Add-On Instructions
I/O modules
Redundancy modules
1756 discrete, analog, and specialty

1756-RM (requires 1756-CN2 or 1756-CN2R and 1756-EN2T)
1757-SRM
Ethernet interface (supervisory network)
1756-EN2T, 1756-EN2F
1756-ENBT
ControlNet interface (peer-to-peer network)
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
I/O interface (downlink)
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
Severs and workstations
Redundant process automation system server (PASS)

Redundant operator workstations (OWS)
Redundant FactoryTalk View SE with automatic switchover
FactoryTalk Live Data services
ControlLogix SIL 1 and SIL 2

Systems
Safe, reliable systems safeguard people, property, the environment, and

reputations. Safety Integrity Level certification makes it simpler, easier, and less
expensive meet growing standards compliance requirements worldwide.
The SIL 2 TYPE certification of ControlLogix controllers assures the
suitability of ControlLogix products for use in safety applications up to and
including SIL 2.
55
Chapter 7
Fault Tolerant Configuration

For SIL applications, a programming
terminal is not normally connected.
Plantwide Ethernet or Serial Network

Overall Safety Loop
Primary Chassis
ControlNet or
EtherNet/IP Network
Connect to other
safety-related
ControlLogix and other
remote I/O chassis.
SIL-2 certified
ControlLogix
components are within
the overall safety loop.
Remote I/O Chassis A
Remote I/O Chassis B
Secondary Chassis
Sensor
Actuator
1492 Termination Board
ControlNet or
EtherNet/IP Network
56
Connect to non-safety related systems outside the

ControlLogix portion of the SIL-2 certified loop.
Chapter 7
Fail Safe Configuration

For SIL applications, a programming
terminal is not normally connected.
This workstation is for diagnostics and visualization

(read-only access to controllers in the safety loop).
Plantwide Ethernet or Serial Network

Overall Safety Loop
Sensor
Actuator
ControlNet or
EtherNet/IP Network
ControlNet or
EtherNet/IP Network
SIL-2 certified
ControlLogix
components are within
the overall safety loop.
Connect to other safety-related

ControlLogix and other remote
I/O chassis.
Connect to non-safety related systems outside the

ControlLogix portion of the SIL-2 certified loop.
Resource
Description
Using ControlLogix in SIL2 Applications Safety Reference Manual,

publication 1756-RM001
ControlLogix components supported in SIL 2 configurations.
http://www.rockwellautomation.com/products/certification
Complete list of ControlLogix products that are certified for SIL 1

and SIL 2 applications
57
Chapter 7
ICS Triplex SIL2 and SIL 3

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

Category
Product
Description
ICS Triplex control system
Trusted systems
Trusted technology uses 3-3-2-0 fault-tolerant control to

virtually eliminate spurious trips. Triple modular redundancy
(TMR) uses majority voting to identify a source of failure.
Available with OPC or CIP integration.
AADvance systems
The AADvance technology is:

configurable for SIL 1, SIL 2, and SIL 3.
scalable redundancy for fault tolerance.
simplex, duplex, or triplex configuration.
integration via OPC or CIP protocols.
ICS Triplex technology is available only as a complete system from ICS

Triplex, a Rockwell Automation company.
Additional Resource
Resource
Description
http://www.icstriplex.com
ICS Triplex, a Rockwell Automation company, products
58
Chapter
Introduction
Domain Controller
The PlantPAx system infrastructure is built on open industry standards to

support seamless integration of the system components, as well as to provide
connectivity to higher level business systems. In addition, the PlantPAx system
leverages best-of-breed technology partners where it makes sense - delivering
maximum value without relying on proprietary hardware and software.
Section
Page
Domain Controller
59
Ethernet Hardware
60
System Software and Services
60
The domain controller is a separate computer. The domain controller must be

local to the workstations and servers and not remote to the system. Do not
load any application software on the domain controller. Load all system
application software on the other computers such as the PASS, application
server, OWS, and EWS.
Computer Requirements - Domain Controller

Attribute
Hardware
Domain Controller
Pentium processor
2.0 GHz CPU
1 GB memory
Software
Windows 2003 server

No application software
Configuration
Hyper-threading optional
DHCP enabled with IP address reservation
Active directory
Kerberos authentication protocol
DNS server
WINS server
No routing
No firewall
No power management
No screen saver
59
Chapter 8
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 topologies.
Stratix 8000 modular managed switches,
Stratix 6000 fixed managed switches
Stratix 2000 unmanaged switches.
Cisco switches
System Software and

Services
Supervisory switches at higher levels of the process system include the Cisco Catalyst
2950 series, managed switch.
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 control.
One place to create, grant rights, and monitor all users of the system
Simplification of regulatory compliance
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 product.
No activation media to manage
Simple method for obtaining a floating or borrowed license
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 system.
Consistent user interface for visualization and management across the entire system
Virtually no HMI alarm configuration required
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 displays.
Define it once, use it everywhere and do not duplicate
Logical naming eases redeployment of physical servers
No central database, no single point of failure
60
Notes:
61
Notes:
62
Notes:
63
64
Rockwell Automation
Support
Rockwell Automation provides technical information on the Web to assist you in

using its products. At http://support.rockwellautomation.com, 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
http://support.rockwellautomation.com.
Installation Assistance
If you experience a problem within the first 24 hours of installation, please review the
information that's contained in this manual. You can also contact a special Customer
Support number for initial help in getting your product up and running.
United States
1.440.646.3434
Monday Friday, 8am 5pm EST
Outside United
States
Please contact your local Rockwell Automation representative for any

technical support issues.
New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational
when shipped from the manufacturing facility. However, if your product is not
functioning and needs to be returned, follow these procedures.
United States
Contact your distributor. You must provide a Customer Support case

number (call the phone number above to obtain one) to your distributor
in order to complete the return process.
Outside United
States
Please contact your local Rockwell Automation representative for the

return procedure.
Publication PROCES-SG001A-EN-P - March 2009 65

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PlantPAx Process

Important User Information

Identifies information about practices or circumstances that can cause an explosion in a

Controller-based Batch Management and Control. . . . . . . . . . . . . . . . 40

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

ControlLogix SIL 1 and SIL 2 Systems. . . . . . . . . . . . . . . . . . . . . . . . . 55

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System

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

The PlantPAx system represents Rockwell Automations culmination of

PlantPAx Process Automation System Overview

The PlantPAx system focuses on these main areas.

The PlantPAx core system consists of:

Field device integration and

Batch management and control

The PlantPAx system enables flexible production, equipment-independent recipe management,

Critical process control and safety

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

Rockwell Automation leverages Integrated Architecture technologies and

Rockwell Automation characterizes a process automation system based on its

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

The independent class architecture is for simpler process control

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

This diagram shows an example process control system based on the

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

Add workstations with dedicated roles to expand the independent class

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

This diagram shows an example process control system based on the

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

The distributed class architecture expands on the centralized class by adding

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

This diagram shows an example process control system based on the

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Process Automation System Overview

Use these system elements in your process architecture.

Independent workstation (single

One EWS required

One EWS required

Can have as many as 5 EWS

Can have as many as 5 EWS

One PASS required and includes:

One PASS required and includes:

1000 alarms with Acks per

1000 alarms with Acks per

50 data log points logged per

50 data log points logged per

One batch server

One batch server

8 remote clients for PASS

1...5 ControlLogix controllers

1...6 ControlLogix controllers

375 total control strategies per

500 total control strategies per

1...6 ControlLogix controllers per

Publication PROCES-SG001A-EN-P - March 2009

PlantPAx Core System

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