Home

proces-sg001 - Literature Library

1. 1 sn Layer 3 with dual Ethernet fiber connections to Layer 2 fiber connections For more information see page 18 dt 4a E on 2 Chl Pod mo Crossload Media 0 gt 3o m Redundant Controllers 2ps l Epe i a T EtherNet IP Device level Ring CAL A AE A A 7 Redundant 1 0 Modules Hele sA et 10 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System High availability encompasses productivity including reliability and maintainability Reliability is the likelihood that a device performs its intended function during a specific period of time Maintainability is the ability of a system to be changed or repaired Table 4 Redundant Element Options System Element Networks Servers Controllers f ji _ gt jj o E J I i I O modules High Availability Options The following applies for Ethernet networks e NIC teaming on servers and workstation uses two physical Ethernet cards on each server and workstation e Dual Ethernet media can connect the NIC cards to two separate level 2 switches e Dual Ethernet fiber media can connect the level 2 switches to separate switches on a level 3 stack e A Device level Ring network can be used to connect the I O racks and devices to your simplex or r
2. EtherNet IP 46273 ini an ey Select a PlantPAx System Select from the following options Drives Soft Starters Across the Line Starters Switch PowerFlex 525 PowerFlex 753 PowerFlex 755 With Automatic Device Configuration a Logix controller can automatically detect a replaced PowerFlex 525 7530 or 755 drive and download all configuration parameters minimizing the need for manual reconfiguration and helping to reduce downtime 1 PowerFlex 753 AC drives require a dual port EtherNet IP communication card Table 37 PowerFlex Drives and Communication Modules Available Communication Modules Drive Cat No Description 258 PowerFlex 525 AC drive with an embedded EtherNet IP port and an embedded Safe Torque Off STO See page 62 for more e information on STO 20F PowerFlex 753 AC drive 206 PowerFlex 755 drive 25 COMM E2P 25 COMM D 25 COMM P 20 750 BNETIP 20 750 CNETC 20 750 DNET 20 750 ENETR 20 750 PBUS 20 750 PNET 20 750 PNET2P 20 COMM C 20 COMM D 20 COMM E 20 COMM H 20 COMM K 20 COMM LY 20 COMM M 20 COMM P 20 COMM 0 20 COMM R S 20 COMM S 1 Fora complete list of catalog numbers see the PowerFlex Low Voltage AC Drives Selection Guide publication PFLEX SG002 Dual port EtherNet IP supports DLR functionality e DeviceNet e PROFIBUS PA BACnet IP option module e Coaxial ControlNet option module DeviceNet option module Dual p
3. 1788 FBJB6 Junction Box G a i E a j u PROFIBUS PA Devices PROFIBUS PA Devices PROFIBUS PA Devices Table 36 PROFIBUS PA Interface PROFIBUS interface 1788 EN2PAR EtherNet IP to PROFIBUS PA linking device Supports redundant PROFIBUS PA media and DLR capable Ethernet network Linking devices have built in terminators 1788 CN2PAR ControlNet to PROFIBUS PA linking device Supports redundant PROFIBUS PA media and redundant ControlNet media Linking devices have built in terminators PROFIBUS network components Both linking devices have built in power conditioning 1788 FBJB4R Intelligent junction box supports redundancy includes four drop ports and four trunk ports 1788 FBJB6 Intelligent junction box with six drop ports and two trunk ports Additional components Pepperl Fuchs PROFIBUS components such as valve couplers surge protectors and distributors See the Encompass website for Pepperl Fuchs product offerings Segment protection Protects against device or line faults with short and open circuit protection Pepperl Fuchs intrinsic safety components such as isolated barrier systems hazardous area enclosures and equipment See the Encompass website for Pepperl Fuchs product offerings PROFIBUS PA device integration tools include the following e Pre engineered controller code with Add On Instructions that provide two way exchange of data between faceplates and the ControlLogix controller e Pre config
4. o EtherNet IP 46274 20 COMM S 20 COMM P 20 COMM C 20 COMM 20 COMM M 20 COMM D 20 COMM E 20 COMM ER 20 COMM H 20 COMM S 20 COMM P 20 COMM C 20 COMM 20 COMM M 20 COMM D 20 COMM E 20 COMM ER 20 COMM H 20 COMM Q SMC Flex SMC 50 ar with E i inl Available Communication Modules RS485 DF1 communication adapter e PROFIBUS DP communication adapter ControlNet communication adapter Coax e Interbus communication adapter e Modbus TCP communication adapter DeviceNet communication adapter e EtherNet IP communication adapter Dual port EtherNet IP communication adapter e HVAC communication adapter RS485 DF1 communication adapter e PROFIBUS DP communication adapter ControlNet communication adapter Coax e Interbus communication adapter e Modbus TCP communication adapter DeviceNet communication adapter EtherNet IP communication adapter Dual port EtherNet IP communication adapter e HVAC communication adapter ControlNet communication adapter Fiber 1 For additional product information see the Smart Motor Controllers SMC 3 SMC Flex and SMC 50 Soft Starters Family Brochure publication 150 BR144 52 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Across the Line Starters We offer a full line of versatile and robust starters for both IEC and NEMA applications
5. FactoryTalk Historian Licenses Category Cat No Description Factorylalk Historian software includes a FactoryTalk VantagePoint software license and one named user client The number of users is cumulative and can be a mixed number of named users and concurrent users If you choose concurrent on the PSE you must purchase a license for the server based on the number of active CPUs on the server Information software Select the Factorylalk Historian SE software tags 95 18 HSE250 e 250 tags 95 18 HSE500 e 500 tags 95 18 HSE1K e 1000 tags 9518 HSE2K5 e 2500 tags 9518 HSESK e 5000 tags 95 18 HSE10K e 10 000 tags 95 18 HSE20K e 20 000 tags 9518 HSE50K e 50 000 tags 8 HSE100K e 100 000 tags ee i ee Y 95 ProcessBook Select for each client that is using ProcessBook e 9518 HPBENE e FactoryTalk Historian ProcessBook Single User e 0518 HPBENF e FactoryTalk Historian ProcessBook Concurrent User Excel Add in Select the following e 9518 HDLENE Factorylalk Historian DataLink Excel Add in Single User e 9518 HDLENE Factorylalk Historian DataLink Excel Add in Concurrent User 1 English version is listed Different languages are available by contacting your local Allen Bradley distributor or Rockwell Automation sales representative AppServ Info VantagePoint AppServ Info can be configured as a decision support tool by using VantagePoint software Table 17 1 AppServ Info VantagePoint Virtual Requirements
6. PASS Redundancy Options PASS servers can be configured as redundant for the following software components e HMI server e Alarm server e Data server Redundancy can be added to be sure of the availability of critical operations For PASS servers you can choose the level of redundancy that you need When a PASS is made redundant typically all of the above elements that are hosted on the PASS are made redundant Redundant PASS servers require duplicate hardware as listed in Table 9 1 Selecting redundant data servers impacts controller memory and communication bandwidth For more information see the following e High Availability Options on page 10 e PlantPAx Process Automation System Reference Manual publication PROCES RMO01 Table 9 1 PASS Virtual Requirements Category Requirement Virtual infrastructure Required e 2vCPU e 4GBvRAM min Recommended CPU and menor allocation e High priority Resource pool Recommended hard drive sizing averages e 40 input output operations per second I0PS e 35 reads sec e 5 writes sec Operating system Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Additional third party software Antivirus software 1 All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation 1 2 See the PlantPAx Reference Manual publication PROCES RM001 for Resource Pool Allocation 3 Che
7. PlantPAx System on a ControlNet Network This diagram shows an example of the PlantPAx system architecture using the EtherNet IP network for supervisory control and with I O communication on the ControlNet network The example is a distributed class for single or multiple PASS servers Domain Application Servers Multiple OWS EWS Controller Ey Il es UM EtherNet IP Network Controller EA E l ContolNet Network FOUNDATION Fieldbus Devices PROFIBUS PA Devices Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System High Availability Options In process automation maintaining critical operations requires doing your engineering best to make sure nothing gets lost stops working or is damaged This generally involves implementing a highly available automation system The PlantPAx platform enables high availability by offering redundancy options at each level of the architecture You can choose the level of redundancy you need without paying for redundant components you don t need wr E Redundant Servers NIC teaming on servers and clients
8. e High Availability options e PlantPAx System Estimator Software Release Information Select e Virtualization e Domain controller e Network topology Ethernet switches Select e PASS server e Engineering workstation e Operator workstation e Independent workstation e Application servers e VMWare Component Sizing Select e Simplex controllers e Redundant controllers Skid based controllers Select e 1 0 product e Process network 1 0 e Field devices Select e Regulatory control options e Supervisory control options Select e ControlLogix SIL 2 systems e AADvance and Trusted SIL 2 SIL 3 and TMR systems e GuardLogix SIL systems SlL rated instruments e PowerFlex SIL 2 and SIL 3 Systems Rockwell Automation Publication PROCES SG001G EN P September 2014 3 Select a PlantPAx System What s New This revision of the PlantPAx Selection Guide updates system rules to support the latest characterized software versions and incorporates additional information on the following topics Topic Description Page System infrastructure moved forward in manual The use of virtualization provides cost savings over traditional 13 physical servers Guidelines changed for server elements Added guidelines for when virtualization is used 21 23 24 25 28 31 33 AppServ OWS added to server section AppServ OWS lets you host multiple thin clients as Operator 25 Workstations from a single server
9. Chassis based 1 0 modules 1756 ControlLogix ol e 1756 EN21 1756 EN21R 1756 EN3TR 1756 EN2F 1756 EN2 TXT 1756 EN2TSC 756 ENBT EtherNet IP modules 756 CN2 1756 CN2R 1756 CNB 1756 CNBR ControlNet modules 756 DNB module 1769 Compact 0 No communication interface required as they re all local to controller chassis Redundant 1 0 1715 Redundant 0 1715 AENTR EtherNet IP adapter Variable frequency drives PowerFlex 525 AC drive e Built in EtherNet IP port and Safe Torque Off e Optional adapters 25 COMM E2P dual port EtherNet IP that supports DLR functionality 25 COMM D DeviceNet 25 COMM P PROFIBUDS DP _ _ For more options see the PowerFlex Low Voltage AC Drives Selection Guide publication PFLEX SG002 PowerFlex 753 AC drive e Optional adapters include the following 20 750 ENETR Dual port EtherNet IP 20 750 CNEIC Coaxial ControlNet 20 750 DNET DeviceNet PowerFlex 755 AC drive e Built in EtherNet IP port e Optional adapters include the following 20 750 ENETR Dual port EtherNet IP 20 750 CNEIC Coaxial ControlNet 20 750 DNET DeviceNet Soft motor starters 150 SMC smart motor controller 20 COMM communication adapters listed on page 52 Rockwell Automation Publication PROCES SG001G EN P September 2014 43 Select a PlantPAx System Table 28 I O Communication Interfaces Category Communication Interface Cat No Overload relays E1 Plus Electronic Ove
10. Our light industrial IEC starters are more environmentally friendly versatile and flexible Our heavy duty NEMA ControlLogix L 7x Eu ate are starters are renowned for a more rugged construction increased TE dependable performance and longer electrical life In addition this i portfolio offers Electronic Overload Relays that provide integration between the starters and Logix controllers The diagnostic capabilities of the overload relays help maximize uptime for motor control in an automation system g EtherNet IP 46275 Table 39 Electronic Overload Relays and Communication Modules Cat No Description Available Communication Modules 193 592 EE E1 Plus Electronic Overload Relays e 193 ETN e EtherNet IP module e 193 EPRB e PROFIBUS module e 193 EDN e DeviceNet module 193 592 C E3 Plus Electronic Overload Relays with embedded DeviceNet 193 DNENCAT EtherNet IP communication auxiliary DeviceNet to EtherNet IP linking device single port 193 DNENCATR EtherNet IP communication auxiliary DeviceNet to EtherNet IP linking device dual port 193 592 300 E300 Electronic Overload Relays 193 ECM ETR EtherNet IP communication module 1 For additional product information see the Bulletin 193 592 and 825 Overload Relay Family Brochure publication 193 BR029 2 For more information see the E300 Electronic Overload Relay Selection Guide publication 193 SG010 Rockwell
11. PASS and AppServ 11 VMWare Components 4 Total CPU resource pool 17 Customer X wants to use 3 servers to have the ability to take 1 server offline for maintenance while maintaining redundancy with the other 2 servers When purchasing servers Customer X must size 2 servers that can withstand the entire load by using the following calculations Cores per server 17 cores 2 servers 9 cores per server Memory per server 71 GB 2 servers 36 GB per server Customer X also plans for future expansion and assumes 30 growth In this scenario Customer X needs to purchase 3 servers with the following specifications Cores per server 9 cores server x 1 30 12 cores server Memory per server 36 GB server x 1 30 47 GB server 38 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Controllers This section explains controller elements how to determine I O count and basic sizing guidelines Review controller sizing and then select from the following options The optimal number of controllers for the PlantPAx system depends i gt eo on the size of your application physical layout of your plant and the e Redundant Controllers design of your process Consider segregating non related process Controllers for skid based Equipment equipment into separate controllers so that maintenance activities in one area do not impact the operation of another area Controllers als
12. Remove units without opening the door and help reduce exposure to electrical hazards with SecureConnect units for CENTERLINE 2100 MCCs ArcShield enclosure options for both 2100 and 2500 MCCs help mitigate and contain arc flash incidents Table 40 Low Voltage Motor Control Centers CENTERLINE 2100 MCC 2100 Designed to meet UL and NEMA standards e Allen Bradley motor control devices starters soft starters and drives e Available with SecureConnect units e ArcShield arc resistant enclosures also available e EtherNet IP and DeviceNet networking e IntelliCENTER software CENTERLINE 2500 MCC 2500 e Designed to meet IEC standards e Allen Bradley motor control devices starters soft starters and drives e ArcShield arc resistant enclosures also available e EtherNet IP and DeviceNet networking e IntelliCENTER software 1 For more information see the website at http www ab rockwellautomation com Motor Control Motor Control Centers 54 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Advanced Process Control Advanced Process Control APC is an umbrella term that covers a Select from the following options wide range of control technologies from simple regulatory loops to C oni complex multi unit optimizations Depending on the context n die vocali walons anything more sophisticated than a simple PID loop can be e Supervisory Control Options considered APC The PlantPAx po
13. a R EREE B w SER i r E i E p oj a E Ik 3 7 T a sE ft ce Le fe ma wi Use these system elements in your process architecture Table 3 Architectures and System Elements System Element Station Architecture Distributed Architecture PASS Single computer serves as PASS EWS and OWS in an independent workstation One PASS required and includes the following e Factorylalk Directory server e HMI server e Data server e Alarms and Events Server Additional PASS as needed up to 10 servers or redundant server pairs EWS Included in independent workstation e 1 EWS required e Can have as many as 5 EWS ows Included in independent workstation Up to 10 remote clients per PASS up to 50 for system Process controller 1 5 ControlLogix controllers 1 8 ControlLogix controllers per PASS data server Application servers AppServ Asset Management as needed AppServ Asset Management as needed AppServ Batch as needed AppServ Batch as needed AppServ Information Management Historian or Reporting as needed AppServ Information Management Historian or Reporting as needed AppServ
14. 2 3 4 y a SS Requirement Required e 2vCPU e 4GBvRAM min Recommended CPU and memory allocation e Normal priority Resource pool Recommended hard drive sizing averages e 10 input output operations per second lOPS e 3reads sec e 7 writes sec Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Antivirus software All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation See the PlantPAx Reference Manual publication PROCES RM001 for Resource Pool Allocation Check with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 18 2 AppServ Asset Traditional Requirements Category Traditional infrastructure Operating system Additional third party software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Requirement The Asset Management server must be installed on server class hardware e Intel Xeon Multicore processor 4 cores or greater e 2 40 GHz CPU e 468 RAM min e Dual hard drives one for application code one f
15. 4 Rockwell Automation Publication PROCES SG001G EN P September 2014 Table 1 Additional Resources Resource Ethernet Design Considerations Reference Manual publication ENET RM002 Industrial Ethernet Media Complete Solution for Ethernet Networks and Integrated Architecture publication 1585 BR001 Converged Plantwide Ethernet CPwE Design and Implementation Guide publication ENET ID001 Product Compatibility and Download Center at http www rockwellautomation com rockwellautomation support pcdc page Field Device Integration FLEX 1 0 and FLEX Ex Selection Guide publication 1794 SG002 POINT 1 0 Selection Guide publication 1 34 SG001 ArmorBlock 1 0 Selection Guide publication 1732 SG001 ArmorPOINT 1 0 selection Guide publication 1738 SG001 http www endress com eh home nst products products instruments Region Locations for Panduit Corporation Product category E H Instruments via HART to PlantPAx User Manual publication PROCES UM002 Process Safety http www rockwellautomation com products certification Using ControlLogix in SIL2 Applications Safety Reference Manual publication 1756 RM001 AADvance Solutions Handbook publication CSTT RM447 AADvance System Build Manual publication ICSTI RM448 AADvance Configuration Guide publication ICSTT RM405 AADvance Safety Manual publication CST T RM446 AADvance Troubleshooting and Repair Manual publication CSTI RM406 Select a PlantPAx System Descriptio
16. Automation Publication PROCES SG001G EN P September 2014 53 Select a PlantPAx System Motor Control Centers As an alternative to wiring EWS Control Room HMI Controller Maintenance PC each device individually a 1 Rockwell Automation offers i ig a E two low voltage motor COTES WEEEEEE r era a a control centers MCC that feature a rugged high EtherNet IP Network performance packaging a solution for all your motor a bet PF m control needs that integrate T u n control and power in one fi zi T centralized location a oe Consider CENTERLINE 2100 a B aF ae or CENTERLINE 2500 MCCs CENTERLINE 2500 MCC Powerflex Drives CENTERLINE 2100 MCC Medium Voltage Equipment to house your starters soft starters and drives to meet IEC UL and NEMA standards Benefit from embedded network systems with IntelliCENTER technology and software EtherNet IP networks provide enhanced integration between the plant floor and corporate operations by using a single programming environment and built in DeviceNet technology is designed and tested to ODVA specifications to help assure reliable communication Use IntelliCENTER software for seamless integration into your Logix architecture and gain valuable access to your MCC operating data CENTERLINE MCCs are available with safety options that help reduce exposure to electrical hazards and arc flash mitigation and containment
17. EtherNet IP module placed in the redundant chassis For an illustration see Chapter 7 in the PlantPAx Process Automation System Reference Manual publication PROCES RMO001 Rockwell Automation Publication PROCES SG001G EN P September 2014 35 Select a PlantPAx System VMware Component Requirements When purchasing hardware take into consideration future expansion plans by possibly adding an additional 20 30 of resources VMware makes it relatively simple to scale the system size upward by adding servers in the future to provide additional resources VMware View is a virtual desktop infrastructure solution that simplifies desktop management and provides you with what you need when you need it The VMware vCenter server provides a centralized platform for managing your VMware vSphere environments Automate and deliver a virtual infrastructure with confidence Both of these require resources from the physical infrastructure to operate and need to be taken into consideration when sizing your system Table 20 VMWare Component Resource Requirements VMWare Components vCPU VRAM VCenter server sizing virtual x64 bit operating system 3GB 4 GB 4 GB Less than 10 ESXI servers 10 50 ESXI servers 50 200 ESXI servers VMWare View server virtual x64 bit operating server 4GB 6 GB 8 GB Less than 25 View desktops Between 25 50 View desktops Between 50 75 View desktops Remember to divide the total system requi
18. FTD 0 Data server HMI server Alarm server FTD Data server HMI server Alarm server Data server Alarm server Data server HMI server Alarm server 46196 Option 4 Logically Segregated Plant into Operational Areas fully independent Data server HMI server Alarm server id Not characterized with the PlantPAx system but a valid configuration HMI server Alarm server 46197 Data server Description This option has all of the essential software components housed in a single PASS server e FID Factorylalk Directory allows for central administration of multiple components that exist on multiple client servers For example security settings in original environments can be shared throughout the PlantPAx system e Data server The data server handles communication between controllers and the servers and workstations Data servers are limited by capacity such as number of OWSs communication of controllers to displays and communication of controllers to data logs or Historian software e HMI server These servers segregate the plant into logical areas also store visualization components
19. elements are unchanged We suggest that you visit the Rockwell Automation Network and Support Services website http www rockwellautomation com services networks for assistance A VM behaves exactly like a physical computer because the VM contains its own virtual CPU RAM hard disk drive and network interface card The VM runs as an isolated guest OS installation The terms host and guest help distinguish the software that is running on the actual machine host and the software that is running on the VM guest The benefits of PlantPAx by using virtualization include increased energy savings reduced system footprint and hardware cost self contained simulation and engineering faster server provisioning increased up time and availability improved disaster recovery isolated applications and extended system life Project teams can choose any hypervisor to run our virtual image templates Flexibility and ease of deployment are key when designing a virtual infrastructure and both are an integral part of the PlantPAx system If the project team needs guidance Rockwell Automation has a partnership with industry leading virtual infrastructure provider VMWare that provides step by step deployment guides for the PlantPAx system When virtualizing your PlantPAx system Rockwell Automation offers virtual image templates as an option to deploy the PlantPAx process automation system The PlantPAx Virtual Image Templates deliver the core
20. hosted and displayed from within FactoryTalk View SE by using the ProcessBook Runtime Rockwell Automation Publication PROCES SG001G EN P September 2014 27 Select a PlantPAx System We recommend that you host FactoryTalk Historian and FactoryTalk VantagePoint applications on separate information management servers The same server requirements apply for each server See Knowledgebase Answer ID 62869 at http www rockwellautomation custhelp com for guidance on whether one or more servers are required AppServ Info Historian One of the ways to configure the AppServ Info is as a historian to collect data Follow these guidelines if you are adding a Historian server to your PlantPAx system Table 16 1 AppServ Info Historian Virtual Requirements Category Requirement Virtual infrastructure Required e 2vCPU e AGBvRAM min Recommended CPU and we allocation e High priority Resource pool Recommended hard drive sizing averages e 100 input output operations per second IOP e 20 reads sec e 80 writes sec Operating system Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Additional third party software Antivirus software 1 All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation 2 See the PlantPAx Reference Manual publication PROCES RMQ01 for Resource Pool Allocation 3 Check with your drive manufacturer f
21. network for the workstations servers and the controllers The EtherNet IP network also supports controller downlinks and EtherNet IP Network connections to remote I O and field device interfaces EtherNet IP is supported by ODVA Field instruments that support a direct connection to EtherNet IP networks include the following e Endress Hauser Promass 83 and compact Promass 100 Coriolis flowmeters for liquid and gas flows w Promass 100 e Endress Hauser Promag 53 electromagnetic flowmeter for conductive liquids Stratix 8000 Table 31 EtherNet IP Interface ControlLogix controller interface 1756 EN2T 1756 EN2TR 1756 EN2F ControlLogix EtherNet IP scanner 1756 ENBT 1756 EWEB 1788 EN2FFR EtherNet IP to FOUNDATION Fieldbus linking device Supports H1 FOUNDATION Fieldbus networks and redundant media 1788 EN2PAR EtherNet IP to PROFIBUS PA linking device Supports redundant PROFIBUS PA media and DLR capable Ethernet network 46 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System ControlNet Devices The ControlNet network is an open control network for real time high throughput applications that use the Common Industrial Protocol CIP to combine the functionality of an I O network and a peer to peer network providing high ControlNet Network speed performance for both functions ControlNet i
22. operation of a controller Defines how to configure an AADvance controller by using the AADvance Workbench to meet your Safety Instrument Function SIF application requirements Defines mandatory standards and makes recommendations to safely apply AADvance controllers for a SIF application Explains how to use tradition al and extreme environment ControlLogix controllers Provides plant maintenance personnel with information on how to trace and repair a fault in an AADvance system and perform routine maintenance tasks You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Notes 6 Rockwell Automation Publication PROCES SG001G EN P September 2014 Welcome and thank you for choosing the PlantPAx Process Automation System The PlantPAx system is an integrated control and information solution that provides plantwide optimization in a wide range of industries This single platform system is built on open industry standards to help support seamless integration of the system components as well as to provide connectivity to high level business systems Select a PlantPAx System System Architectures Review these options e Process System Elements e PlantPAx System Arc
23. system elements as pre configured drop in templates on a USB device Virtual image templates are delivered in an open virtual format file and are officially supported and tested for use with VMWare vSphere The pre installed and pre configured virtual image templates help to reduce validation costs and initial engineering time simplify upgrades and patch management and enhance scalability Only one copy of the virtual image templates is needed for a project Each server or workstation instance deployed from a template needs its own software licenses for the associated operating system and Rockwell Automation software The PlantPAx templates are designed for use with Microsoft Volume Licensing For more information see the following e Virtual Images Templates User Manual publication 9528 UM001 Describes the PlantPAx virtual images for the deployment of the PlantPAx system on virtual architectures e PlantPAx Process Automation System Reference Manual publication PROCES RMO01 Provides recommendations and guidelines for best practice of system architecture and elements Rockwell Automation Publication PROCES SG001G EN P September 2014 13 Select a PlantPAx System Table 5 Virtual Image Templates Virtual templates 9528 PAXVTENE USB device that contains three virtual image templates PASS EWS and OWS Each template contains a Microsoft Windows operating system with all required Rockwell Automation software pre installed but
24. 001G EN P September 2014 17 Select a PlantPAx System Ethernet Switches A network switch is a computer networking device that is used to connect devices on a computer network by performing a form of packet switching A switch is considered more advanced than a hub because a switch sends a message only to the device that needs or requests it rather than broadcasting the same message out of each of its ports The collaboration of Rockwell Automation with Cisco on products services and educational resources PlantPAx helos manufacturers and machine builders converge and simplify their network architecture and tightly integrate technical and business systems by using EtherNet IP and industrial grade Ethernet switches All applications require proper configuration to achieve the best system performance If you do not configure the managed switch it s possible that system performance can be adversely affected We recommend that you contact your system administrator if there are any doubts on the installation and configuration Table 8 Ethernet Switches e Supervisory Layer 3 switches Fiber e Routing information to other networks Stratix 8300 e Cisco Catalyst 3560G or equivalent e Cisco Catalyst 3750x or equivalent e Cisco Catalyst 3850 e Connecting control hardware sensors and workstations Layer 2 switches 1585 series copper media e Isolated networks e Stratix 8000 e Stratix 6000 e Stratix 5700 e Cisco Catalyst
25. 1734 POINT 1 0 The 1715 I O system supports as many as 24 I O modules per set of adapters Table 29 1715 I O Modules Cat No Description 1715 1B16D 16 point 24V DC diagnostic input module 1715 OB8DE 8 point 24V DC diagnostic output module electronically fused 1715 IF16 16 channel 4 20 mA current analog input module 1715 OF8I 8 channel 4 20 mA current analog output module isolated For more information on the communication and usage based on the selected I O family refer to the following Rockwell Automation literature 44 Rockwell Automation Publication PROCES SG001G EN P September 2014 e Redundant I O System User Manual publication Select a PlantPAx System 1715 UMO001 e ControlLogix Selection Guide publication 1756 SGO001 e CompactLogix Selection Guide publication 1769 SG001 e POINT I O Selection Guide publication 1734 SG001 e FLEX I O and FLEX Ex Selection Guide publication 1794 SGO002 Table 30 shows some of the modules that you can add to the Controller Organizer in RSLogix 5000 software when the controller is in Run mode Table 30 Online Addition of Module and Connection Types Module Type and Communication Method Digital direct Digital rack optimized Analog direct Generic third party direct 1756 DNB In Remote Chassis via a EtherNet IP Network Scheduled Unscheduled Scheduled Unscheduled Yes Yes Yes No Yes Yes Yes N A N A Yes No Yes Noo Yes Yes Yes Yes Yes Yes No Yes
26. 2960G or equivalent Layer 2 3 Services Router Stratix 5900 Layer 2 Wireless Access Point Workgroup Bridge Stratix 5100 High availability at switch level Layer 3 switch Fiber e Cisco Catalyst 3750x or equivalent e Cisco Catalyst 3850 1 For uplink cables between Layer 2 3 fiber is recommended for 1 GB connectivity 18 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Servers and Workstations The supervisory layer of the PlantPAx system can include Select from the following options several servers and workstations This section explains the e PASS Server following server and workstation system elements to help Engineering Workstation EWS you define a bill of material PASS Server e Operator Workstation OWS e Operator Workstation Application Server AppServ OWS e Independent Workstation IndWS e Information Management Application Server AppServ Info e AppServ Info Historian The Process Automation System Server PASS is a required e AppServ Info VantagePoint system element that hosts essential software components Asset Management Server AppServ Asset to run the system The essential software components e Batch Management Server AppServ Batch include the data server HMI server and alarm server e VMware Component Requirements e Virtual Sizing Example You need to determine how many PASS servers are needed for your architecture If your system r
27. 756 L74 or 1756 L75 controller Redundancy module 1756 RM2 Ethernet interface 1756 EN2TR 1783 ETAP 1783 ETAP1E 1783 ETAP2F DLR support e 1756 EN21 1756 ENBT 1756 EWEB 1756 EN2F no DLR support e 1756 EN2TSC secure connection support ControlNet interface if applicable 1756 CN2 1756 CN2R e 1756 CNB 1756 CNBR 1 The PlantPAx system recommendation is to use only one redundant controller in a chassis with a 1756 RM2 redundancy module While a 1756 RM2 module can support two controllers the resulting performance of each controller is not easily predicted Table 26 Redundant ControlLogix Controller Sizing Total 1 0 recommended max 2250 Total tags max 112 500 Recommended control strategies max 450 Total control strategies 250 ms max 120 Total control strategies 500 ms max 220 Tags sec delivered to data server max 20 000 1 These values are recommended maximum limits It s possible that achieving all of these values in a single controller is not doable For more detailed sizing you can use the PSE see page 12 2 Maximum controller strategy is based on all controller strategies being simple regulatory control See Process Controller 1 0 Considerations in the PlantPAx Process Automation System Reference Manual publication PROCES RM001 Rockwell Automation Publication PROCES SG001G EN P September 2014 41 Select a PlantPAx System Controllers for Skid based Equipment The PlantPAx Process Autom
28. A Al 2x8 16 4 20 mA AO X9 3 24V DC DI 2x 16 32 MCC 6x6 36 6Al 6 AO 12 DI 12 DO Smart instruments 2x3 6 6A Controller I O count 98 1 By using this method you are overusing alarm estimation Our recommendation is to reduce the percentage of potential alarms used in the PSE Rockwell Automation Publication PROCES SG001G EN P September 2014 39 Select a PlantPAx System Simplex Controllers Non redundant controllers are referred to as simplex controllers Table 23 Simplex Controller Hardware Requirements Category Cat No Process controller 2 ControlLogix 1756 L71 1756 L72 1756 L73 1756 L74 or 1756 L75 controller Ethernet interface e 1756 EN2TR 1783 ETAP 1783 ETAP1F 1783 ETAP2F Supports device level ring topology 1756 EN21 1756 ENBT 1756 EWEB 1756 EN2F e 1756 EN2TSC for supported secure connections ControlNet interface if applicable e 1756 CN2 1756 CN2R e 1756 CNB 1756 CNBR 1 lfenvironmental conditions warrant you can use an extreme temperature module for example the 1756 L74XT 2 Fora PlantPAx system we recommend that you use the 1756 L7x controller family The 1756 L6x controller family is supported for existing applications Use the PSE if sizing information is required Table 24 Simplex ControlLogix Controller Sizing User memory 16 MB 32 MB Total 1 0 recommended max 375 750 2250 Total tags max 112 500 112 500 Recommended control strategies max ee 450 450 Total
29. AMmin e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Antivirus software 2 2 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Use the following licensing considerations when configuring AppServ Info with VantagePoint software Table 17 3 FactoryTalk VantagePoint Licenses Category Cat No Description Factorylalk VantagePoint software license s consist of user clients Ihe number of users is cumulative and can be a mixed number of named users and concurrent users If you choose concurrent on the PSE you must purchase a license for the server based on the number of active CPUs on the server Information software Information licenses Data connectors Select the following 9521 VPSERVERENE Select one or more of the following for FactoryTalk VantagePoint Client named users 9521 VPNLOTENE 9521 VPNLOZENE 9521 VPNLOSENE 9521 VPNLOIOENE 9521 VPNLO25ENE 9521 VPNLOSOENE Select one or more of the following for FactoryTalk VantagePoint Client concurrent users 9521 VPCLOTENE 9521 VPCLO3ENE 9521 VPCLOSENE 9521 VPCLOIOENE 9521 VPCLO25ENE 9521 VPCLOSOENE If VantagePoint is being used for concurrent user
30. Aggregation Control Protocol LACP provide additional bandwidth between two devices by aggregating multiple Ethernet connections into a higher bandwidth virtual connection These protocols quickly recover from the loss of one or more channel members e Flex Links is a Cisco proprietary resiliency protocol that is for use in redundant star networks This protocol connects an access switch to a distribution switch Rockwell Automation Publication PROCES SG001G EN P September 2014 15 Select a PlantPAx System Table 7 1 O Network Device level ring DLR Recommended for control and 1 0 networks Linear network Star Redundant ControlNet media ControlLogix Controller 1756 CN2R or 1756 CNBR Redundant ControlNet Media or ControlNet Nodes w Bi E A DLR network is a single fault tolerant ring network intended for the interconnection of automation devices This topology has switches embedded into the end devices themselves no additional switches are required The DLR topology does require additional effort to implement and use as compared to a linear network Adv
31. AppServ Info virtual image template added Added information on virtual image template for Historian 28 server VMWare component resources and sizing listed VMware View and VMware vCenter solutions help you size 36 build and manage your virtual platforms Intelligent motor control connections added Motor control solutions including drives soft starters and 51 relays complement a variety of application requirements AADvance Control Systems section features Documentation explains the features performance and 5 61 additional resources functionality of the AADvance controller and systems Powertlex safety systems added to section SIL ratings listed for PowerFlex 525 753 and 755 drives 62 Additional Resources These documents contain additional information concerning related products from Rockwell Automation Table 1 Additional Resources Resource System Core PlantPAx System Application Templates Quick Start publication PROCES QS001 PlantPAx Hardware Specifications and Certifications publication PROCES SRO27 Knowledgebase Answer ID 62366 at http www rockwellautomation com knowledgebase ControlLogix System User Manual publication 1756 UM001 ControlLogix Selection Guide publication 1756 SG001 CompactLogix Selection Guide publication 1769 56001 Process Automation System Training Curriculum publication PROCES CAQ01A EN P Redundant 1 0 System User Manual publication 1715 UM001 http www rockwellautomation com solu
32. Ax system characterization e Intel Core 2 Duo e 2 40 GHz CPU e 4GB RAM min e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 7 Professional SP1 operating system 64 bit Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 10 3 EWS Automation System Software and License Virtual Image Template One per project if using virtualization and virtual USB device contains a virtual image template that has pre installed all applications that are image templates required on the EWS 9528 PAXVTENE Rockwell Automation software license For each EWS Software activation license for the EWS for virtual and traditional environments 9528 EWSLICENE 1 This EWS software license is equivalent to a FactoryTalk View Studio license 9701 VWSTENE and RSLogix 5000 Professional software license 9324 RLD700NXENE You can use the PlantPAx or FactoryTalk View Studio and RSLogix 5000 Professional software licenses with the EWS Rockwell Automation Publication PROCES SG001G EN P September 2014 23 Select a PlantPAx System Operator Workstation OWS The operator workstation OWS provides the graphical view and interface into the process The OWS s
33. C 61508 The instructions of the associated Safety Reference Manual and User Manuals are to be considered ControlLogix SIL 2 systems use the same programming software and data interfaces as used for basic process control on the PlantPAx system The hardware that is used for process safety must be dedicated for process safety applications Specific hardware firmware revisions and software versions are required to meet SIL certifications To make sure you have the correct equipment see the Using ControlLogix in SIL 2 Application Safety Reference Manual publication 1756 RM001 AADvance and Trusted SIL2 SIL3 and TMR systems Diverse SIL 2 and SIL 3 systems use different hardware and software platforms for process safety applications than what is used for basic process control on the PlantPAx system Triple redundancy eliminates the possibility of any single component failure causing a spurious or false trip Diverse process safety integrates with the basic process control on the PlantPAx system by using CIP connectivity including profile support in RSLogix 5000 software AADvance or via OPC connectivity AADvance or Trusted Both the Trusted and AADvance systems share a common Ethernet IP network within a PlantPAx system In addition AADvance and Trusted support redundant Ethernet networks while the AADvance system supports the CIP producer and consumer communication protocol 60 Rockwell Automation Publication PROCES SG001G EN P Septe
34. Category Requirement Virtual infrastructure Required e 2vCPU e AGBvRAM min Recommended CPU and memory allocation e Normal priority Resource pool Recommended hard drive sizing averages e 100 input output operations per second IOPS e 20 reads sec e 80 writes sec Operating system Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Additional third party software Antivirus software 1 All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation 2 See the PlantPAx Reference Manual publication PROCES RM001 for Resource Pool Allocation 3 Check with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed 4 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Rockwell Automation Publication PROCES SG001G EN P September 2014 29 Select a PlantPAx System Table 17 2 AppServ Info VantagePoint Traditional Requirements Category Traditional infrastructure Operating system Additional third party software 1 A Microsoft Excel software license is required Requirement The Information Management server must be installed on server class hardware e Intel Xeon Multicore processor 4 cores or greater e 2 40 GHz CPU e 4GBR
35. Factorylalk Batch 1 unit 9358 FIBO3ENE e Factorylalk Batch 3 units 9358 FIB10ENE e Factorylalk Batch 10 units 9358 FIB30ENE e Factorylalk Batch 30 units 9358 FTBOOENE Factorylalk Batch 60 units Ifa back up server is enabled on the PlantPAx System Estimator an additional server is added to the BOM with an equal number of back up server unit licenses 9358 FTBKYOTENE e Factorylalk Batch Back up Key 1 unit 9358 FIBKYO3ENE e Factorylalk Batch Back up Key 3 units 9358 FTBKY 10ENE Factorylalk Batch Back up Key 10 units 9358 FTBKY30ENE e Factorylalk Batch Back up Key 30 units 9358 FTBKY60ENE e Factorylalk Batch Back up Key 60 units Table 19 4 Batch Server Software for eProcedure software only Batch software and licenses eProcedure software can be licensed separately and used in a non batch server application If you are using Factorylalk Batch these separate licenses are included and not required 9358 EPO3ENE RSBizware eProcedure 3 units e 9358 EP10ENE e RSBizwire eProcedure 10 units e 9358 EP30ENE e RSBizwire eProcedure 30 units e 9358 EP60ENE e RSBizwire eProcedure 60 units If Procedure back up procedures are to be used select one of the following 9358 EPBKYO3ENE e RSBizware eProcedure Back up key 3 units e 9358 EPBKY 10ENE e RSBizware eProcedure Back up key 10 units 9358 EPBKY30ENE e RSBizware eProcedure Back up key 30 units 9358 EPBKY60ENE e RSBizware eProcedure Back up key 60 u
36. HART Devices HART is an open protocol designed to connect analog devices The PlantPAx system interfaces both directly and via remote I O modules to provide a single termination point to gather analog process variables and the additional HART digital data 3 E HART Devices Table 34 HART Interface Chassis based 1 0 modules 1756 IF8H 1756 OF8H ControlLogix analog 1 0 modules with the following 1756 IF16H e Standard profiles in RSLogix 5000 software e DIMs 1756 IF8IH 1756 OF8IH ControlLogix analog isolated 1 0 modules MVI56 HART ProSoft Technology HART multi drop communication interface module for ControlLogix system for use in FactoryTalk AssetCentre Process Device Configuration or other asset management system based on FDT Technology lEC 62453 ISA103 Distributed 1 0 modules 1734 sc IF4H Spectrum Controls analog input module with HART for the POINT 1 0 system 1769 sc IF4IH 1769 sc OF4IH Spectrum Controls analog isolated input and output modules with HART for Compact O modules 1794 lE8H 1794 OE8H FLEX analog 1 0 and FLEX Ex analog 1 0 modules with the following 1794 IF8IH 1794 OF8IH e Standard profiles in RSLogix 5000 software 1797 IE8H 1797 OE8H e DIMs Multiplexers gateways Wireless HART adapter Pepperl Fuchs wireless HART adapter See the Encompass website for Pepperl Fuchs product offerings Network configuration Handheld device Endress Hauser handheld configuration
37. OWS as needed 1 The actual number of OWS controllers supported can vary based on controller selection OWS configuration and overall system loading Use the PlantPAx System Estimator PSE to verify your system design The PSE allows you to verify your application beyond these basic guidelines 8 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System PlantPAx System on an EtherNet IP Network The PlantPAx system is built on open industry standards leveraging the EtherNet IP network as its backbone to help support seamless integration of the system components as well as to provide connectivity to higher level business systems The PlantPAx system supports the ControlNet or EtherNet IP networks for device level communication to deliver a business solution with real time results from the plant floor to the top floor penal Application Servers Multiple OWS EWS PASS Controller 4 _ 3 o ii Redundant Controllers opes r Ei Device level Ring Topology Star Topology a gt gt m k a mn ni il i Fa ss f t i a HHHH IHH j Sane ae HII WE f i
38. Selection Guide PAX Process Automation System System Release 3 0 2014 update Allen Bradley Rockwell Software Automation PlantPAx Process Automation System PlantPAx System Scope The PlantPAx Process Automation System is a modern distributed control system DCS The system is built on a standards based architecture by using Integrated Architecture components that enable multi disciplined control and premier integration with the Rockwell Automation intelligent motor control portfolio Our scalable platform provides you with the flexibility to implement a system appropriate for your application With the PlantPAx system we prescribe a very specific system architecture with defined system elements each with a specific responsibility and detailed specifications Figure 1 PlantPAx System Implementation and Documentation Strategy E a Develop END E an m Define and Bulld p Prep p Specific p Completed a Application System E Eg Virtual Image Templates Quick Start Reference Manual Reference Manual Library of Process Objects Library of Logix Diagnostic Objects Library of Steam Table Instructions 46273 e Define and Procure Helps you understand the elements of PlantPAx to make sure you buy the proper components Build Provides direction on how to implement the PlantPAx server architecture to help develop your application e Prep Provides guidance on how to get started and learn the best prac
39. System Field Networks and I O Field networks and I O components connect process instrumentation and field devices to the PlantPAx system to provide real time data Select from the following options e O Products e Process Network I O e Field Devices I O Products The PlantPAx system supports several families of I O from controller chassis based 1756 and 1769 to smaller distributed I O 1734 and 1794 Table 28 shows available I O families as well as the interfaces to connect to the controller Table 28 I O Communication Interfaces Category Communication Interface Cat No In cabinet 1 0 modules 1734 POINT 1 0 e 1734 AENT 1734 AENTR EtherNet IP adapter e 1734 ACNR ControlNet adapter redundant e 1734 ADN 1734 ADNX 1734 PDN DeviceNet adapter 1790 CompactBlock LDX 1 0 Built in DeviceNet connectivity 1794 FLEX 1 0 1794 AENT EtherNet IP adapter e 1794 AENTR EtherNet IP adapter e 1794 ACN15 1794 ACNR15 1794 ACN15K 1794 ACNR15K ControlNet adapter e 1794 ADN 1794 ADNK DeviceNet adapter 1797 FLEX Ex intrinsically safe 1 0 1794 adapter with 1797 BIC isolator and 1797 CEC connector On Machine 1 0 modules 1732 ArmorBlock 0 Built in EtherNet IP or DeviceNet connectivity 1738 ArmorPOINT 1 0 e 1738 AENT 1738 AENTR EtherNet IP adapter 1738 ACNR ControlNet adapter e 1738 ADN12 1738 ADN18 1738 ADN18P 1738 ADNX DeviceNet adapter 1799 Embedded 0 Built in EtherNet IP and DeviceNet connectivity
40. Yes Yes In Local Chassis In Remote Chassis via a ControlNet Network 1756 CNx no connection Yes Yes Yes Yes Noo Yes N A N A Generic ControlNet N A N A Yes Yes third party direct ane Yes N A N A 1788 CN2FFR linking device N A N A Yes Yes No Yes N A N A 1788 EN2PAR linking device N A N A N A N A N A N A Yes Yes 1788 CN2PAR linking device N A N A Yes Yes Noo Yes N A N A 1715 Redundant 1 0 Generic EtherNet IP N A N A N A N A N A N A Yes Yes third party direct 1756 ENx no connection 1756 ENx rack optimized Rockwell Automation Publication PROCES SG001G EN P September 2014 45 Select a PlantPAx System Process Network I O Use of smart instrumentation has increased in the marketplace This enables the PlantPAx system to leverage the devices improved data and control capabilities In a PlantPAx system the controllers P oa are connected to the field devices via field device components and communicate through the EtherNet IP DeviceNet ControlNet FOUNDATION Fieldbus and PROFIBUS PA networks or by using Encompass the HART protocol Product Partner Many I O and field device products are available via the Encompass third party product referencing program To sort and filter products from best in industry suppliers in your region see http www rockwellautomation com encompass EtherNet IP Devices In a PlantPAx system the EtherNet IP network provides the communication backbone for the supervisory
41. and diagnostic device See the Encompass website for Endress Hauser product offerings HART device integration tools include the following e Pre engineered controller code with Add On Instructions that provide two way exchange of data between faceplates and the ControlLogix controller e Pre configured operator faceplates that provide visualization of instruments connected to the network interface e Field Device Tool Device Type Manager FDT DTM technology allows access to field device configuration and diagnostics via FDT Frames such as FactoryTalk AssetCentre 48 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System FOUNDATION Fieldbus Devices The FOUNDATION Fieldbus network is a protocol designed for robust distributed control of process control applications Devices connected by a FOUNDATION Fieldbus network can be used for sophisticated process control with seamless data distribution from the H1 device level network PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNet IP and ControlNet linking devices as shown in the examples below Other configurations are available for simple and redundant topologies EtherNet IP Linear FtherNet IP Device Level Ring Redundant ControlNet J af a a E ujoja E i e Ojaja enue EtherN
42. antages Disadvantages Ability to survive a single point of failure or a e Supervisor node configuration required device being powered down on the ring e Loss of network service in case of a connection Simplified cabling failure of a single component Ability to cover long distances with 100 m allowed between each copper segment Very fast network convergence Fiber segment can be up to 2 km by using an Etap 1F or 2F No required additional switch A linear network is a collection of devices that are daisy chained together The EtherNet IP embedded switch technology allows this topology to be implemented at the device level No additional switches are required A linear topology works best for a limited number of nodes Advantages Disadvantages Easy to design configure and implement e Loss of network service in case of a connection Least amount of cabling failure of a single component isenivalammountorcolenceded e Creates the potential for congestion problems Variable number of hops can make performance Ability t long dist ith 100 ility to cover long distances wi m difficult to predict allowed between each link Fiber segment can be up to 2 km by using an Etap 1F or 2F No required additional switch The Star is the most common EtherNet IP network where devices are connected and communicate with each other via a switch Nodes are typically grouped closely together Advantages Disadvantages East to design c
43. applications and printers with the use of a single user name and password combination PlantPAx uses a domain controller to store user account information authenticate users and enforce security policies Domain authentication whether it s an existing domain or a new one is recommended Follow these guidelines for the domain controller A domain controller is required if there are 10 or more workstations or servers The domain controllers are separate computers Do not load any application software on a domain controller Load all system application software on the other computers such as the PASS application server OWS and EWS Microsoft support does not recommend running applications on a domain controller and certainly not applications that require more than Authenticated User privileges to run The domain controllers must be local to the system workstations and servers within the local firewall and not remote to the system Domain servers must be configured to include Domain Name Service DNS that lets you identify devices by name rather than IP addresses For redundancy purposes we recommend that you use at least two domain controllers in the domain These domain controllers replicate automatically to provide high availability and an online configuration backup For more domain recommendations see the PlantPAx Process Automation System Reference Manual publication PROCES RMO001 Rockwell Automation Publication PROCES SG
44. are optional 9515 ASTCLMANENE e Factorylalk AssetCentre calibration management 95 15 ASTCLWRKENE e Factorylalk AssetCentre calibration management remote workstation 9515 ASTCLFELKENE e Factorylalk AssetCentre calibration management FLUKE documenting calibration 9515 ASTCLDRKENE e FactoryTalk AssetCentre calibration management Druck documenting calibration 9515 ASTCLTMNENE e Factorylalk AssetCentre calibration management Irnsmtn calibration 1 Additional licenses are available for disaster recovery and calibration management English version is listed Different languages are available by contacting your local Allen Bradley distributor or Rockwell Automation sales representative 32 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Batch Management Server AppServ Batch The batch management server AppServ Batch offers equipment independent recipe management batch independent equipment control and regulatory compliance System size varies from small to large and system requirements vary from simple to complex Basic solutions provide capabilities for small or simple systems to use core system functions including Logix5000 controllers and FactoryTalk View HMI Generally these solutions do not need the functionality provided by server based FactoryTalk Batch software solutions Comprehensive solutions provide capability for large or complex systems to use modular software components This includ
45. ation System is a complete scalable system from single controller to a fully distributed set of equipment You can integrate skid based equipment into the overall system The CompactLogix controller platform offers a solution for skid based equipment to be part of the overall PlantPAx system if the application requires the following e Control of multiple loops for temperature pressure flow or level e Operating as a sub system with sequencing and automation e Controlled as part of the overall process accepting reference inputs and delivering process variables to a supervisory controller Table 27 Skid based Controller Sizing Category CompactLogix 1769 L24ER QBFC1B CompactLogix 1769 L33ER User memory 0 75 MB 2 0 MB Total tags max 4000 12 800 Recommended control strategies max Total control strategies 250 ms max 30 Total control strategies 500 ms max Tags sec delivered to data server max 3000 3000 1 These values are recommended maximum limits It s possible that achieving all of these values in a single controller is not doable For more detailed sizing you can use the PSE see page 12 2 Maximum controller strategy is based on all controller strategies being simple regulatory control See Process Controller 1 0 Considerations in the PlantPAx Process Automation System Reference Manual publication PROCES RM001 42 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx
46. ation offers the PlantPAx System Estimator PSE as part of the Eg PlantPAx Process Automation System Integrated Architecture Builder IAB tool The PSE lets you define your PlantPAx system and verifies that your architecture and system elements are sized properly Jeres Preherenced Server O Sumer Fine SE Server Loarei foe 250 Display Hew BC R F Redundant Server Number of Digtal Inputs ER Tags per OAS actin on Sareen 1i Additional T f Humber of Digtal Outputs ia The PSE creates a new workspace and Historian Datateg etc 50 uas oe ee P Additional Losi Updste Rate z set f nam opens a wizard shown at right to guide RES Additions Alanre O es Hunber of Analog Outputs mo you through selecting system elements Alar Update Rate E SEE apn Existing and sizing the system based on the rules sair r s Haaber cf Digtal inputs e and recommendations from PlantPAx a 1 see amber of Oeics ET T 7 Server Summary system characterization Systern Certs Eau Haber of Analog Inps e Server Charts E Humber of Analog Outputs jo f h e The following items are created based on P a Controles f i l L TA your inputs a eet PT ae l P Sonn on S 2 Potential Tags in Henery HHA e Supervisory Ethernet network with ER 4 hima Fags on all servers operator and iy fo Sever Historian eee m engineering workstations and RA Asset Mg Serves J controller chassis e Listing of required software catalog num
47. ber 2014 Select a PlantPAx System System Infrastructure In building infrastructure you must decide whether your server and client workstations are in a virtual or traditional environment Traditional for our purposes Means One operating system OS that is natively on one computer Virtual machines are hardware independent not tied directly to a specific hardware or OS Select from the following options e Virtual Infrastructure e Traditional Infrastructure e Domain Controller e Network Topologies This section describes the basics of the virtual platform network Ethernet Switches topology and Ethernet switches to help you select your system infrastructure Virtual Infrastructure Virtualization breaks the dependency between operating system and physical hardware allowing multiple virtual machines VMs to run different operating systems and applications from varying locations on the same server This versatility helps to reduce footprint consolidates hardware and increases server utilization You also can upgrade hardware without replacing the operating system on server or workstation system elements thus reducing downtime and maintenance costs If you are considering virtualization you do not purchase specific server or workstation hardware for each system element being virtualized You need the servers storage and network hardware only for your virtual infrastructure that hosts the system elements Otherwise your system
48. bers e ControlNet or Ethernet network for each controller that includes all I O requirements e Various hardware views to support the various devices and chassis Configure iisndware upon Finish ae ee After selecting the system elements as defined in this guide use the PSE tool to modify their properties to create a bill of material BOM in conjunction with the IAB tool The BOM includes controllers I O networks drives cabling and wiring and other devices that comprise your Process Automation System To access the IAB tool to use the PSE see http www rockwellautomation com en e tools configuration html Software Release Information The rules contained within this selection guide are based on using the following characterized software releases e RSLogix 5000 software version 20 x e FactoryTalk View software version 8 0 e FactoryTalk Batch software version 12 00 e FactoryTalk AssetCentre software version 5 0 or later e FactoryTalk VantagePoint software version 5 0 or later e FactoryTalk Historian software version 4 0 or later Performance guidelines are based on the use of the software versions listed above For new PlantPAx systems we recommend that you use these versions of software For the latest compatible software information see the Product Compatibility and Download Center at http www rockwellautomation com rockwellautomation support pcdc page 12 Rockwell Automation Publication PROCES SG001G EN P Septem
49. ble process historian that provides real time access to reliable information e Provides data capture management and analytical capabilities to support decision making e Auto Discovery and Auto Configuration features reduce deployment time and lower total cost of ownership An additional AppServ Info server can be considered for the storage of transactional data You can select a Microsoft SQL server database to act as the central collection point for event based data e Factorylalk Alarms and Events data e Factorylalk Batch data This can be installed on an Information Management server or another server on your system Decision support strategies incorporate the tools described in Table 15 Table 15 Decision Support Options Category Description Factorylalk VantagePoint software An Information Management server is required to host this web based reporting software that brings all data together into a single decision support system e All manufacturing data is accessible in real time e Published reports current dashboards and real time KPIs viewable via web browser e Pre configured reports trends and dashboards e Enhanced HMI trending available by using FactoryTalk VantagePoint Trend Active X within FactoryTalk View SE Factorylalk Historian ProcessBook software An Information Management server is required to enable ProcessBook content standard ProcessBook displays SQC view batch view alarm view The content is to be
50. ck with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed 4 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at _https www rockwellautomation custhelp com Table 9 2 Pass Traditional Requirements Category Requirement Traditional infrastructure The PASS must be installed on server class hardware The following are sample specifications based on PlantPAx system characterization e Intel Xeon Multicore processor 4 cores or greater e 2 40 GHz CPU e 4GB RAM min e Dual hard drives one for application code one for logging if data logging is used or for historian data collection buffering if historian is used e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at https www rockwellautomation custhelp com Rockwell Automation Publication PROCES SG001G EN P September 2014 21 Select a PlantPAx System The PASS requires that you purchase visualization software licenses depending on the number of displays
51. control strategies 250 ms max 0 125 250 250 250 Total control strategies 500 ms max C 450 Tags sec delivered to data server max 20 000 1 These values are recommended maximum limits It s possible that achieving all of these values in a single controller is not doable For more detailed sizing you can use the PSE see page 12 2 The advantages to using the 1756 L75 controller are to maintain common spare parts with redundant systems or if you are doing some memory intensive storage for data or trending not accounted for in sizing model 3 Maximum controller strategy is based on all controller strategies being simple regulatory control See Process Controller 1 0 Considerations in the PlantPAx Process Automation System Reference Manual publication PROCES RM001 40 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Redundant Controllers ControlLogix controllers support redundancy on ControlNet and EtherNet IP networks In a redundant controller system on the PlantPAx system you need these components e Two 1 56 chassis each set up the same with the following Number of slots Modules in the same slots Redundancy firmware revisions in each module Two additional ControlNet or Ethernet nodes outside the redundant chassis pair e One 1756 RM2 module per chassis Table 25 Redundant Controller Hardware Requirements Category Cat No Process controller ControlLogix 1756 L73 1
52. dbus device integration tools include the following e Pre engineered controller code with Add On Instructions that provide two way exchange of data between faceplates and the ControlLogix controller e Pre configured operator faceplates that provide visualization of instruments connected to the network interface e Field Device Tool Device Type Manager FDT DTM technology allows access to field device configuration and diagnostics via FDT Frames such as FactoryTalk AssetCentre In addition the Rockwell Automation FDT ThinFrame read only can be launched via the Add On Profile providing access to each field device status and extended diagnostics Rockwell Automation Publication PROCES SG001G EN P September 2014 49 Select a PlantPAx System PROFIBUS PA Devices The PROFIBUS PA network is the PROFIBUS solution for process automation The PROFIBUS PA network connects automation systems and process control systems with field devices such as flow level pressure and temperature transmitters PlantPAx systems communicate with PROFIBUS PA fieldbus devices through EtherNet IP and ControlNet linking devices as shown in the examples below Other configurations are available for simple and redundant topologies EtherNet IP Linear EtherNet IP Device Level Ring Redundant ControlNet EtherNet IP Network i EtherNet IP Network 1788 EN2PAR Linking Device
53. device contains a virtual template for the AppServ OWS image templates 9528 APPOWSENE Rockwell Automation software license For each client that is being served by the Software activation license for the OWS client that is being served by the AppServ OWS IMPORTANT Client license has to be per AppServ OWS up to 10 per server OWS client not per AppServ OWS 9528 OWSLICENE 1 This PlantPAx software license is equivalent to a FactoryTalk View SE Client license 9701 VWSCWAENE You can use either a PlantPAx or FactoryTalk View SE software license with the OWS Rockwell Automation Publication PROCES SG001G EN P September 2014 25 Select a PlantPAx System Independent Workstation IndWS The independent workstation IndWS combines the roles of the PASS EWS and OWS in one computer This workstation which is also referred to as a network station is a client machine that is connected to a server and can be used as a shadow system for emergency purposes Table 13 1 IndWS Traditional Requirements Category Requirement Traditional infrastructure The IndWS must be installed on workstation class hardware The following are sample specifications based on PlantPAx system characterization e Intel Core 2 Duo 2 40 GHz CPU e 8GBRAM e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 7 Professional SP1 ope
54. e one or a combination of technologies Table 45 Process Safety System Capabilities Process Safety System Specification ControlLogix GuardLogix Trusted 1 a es Fail safe only Yes Yes Yes No Fault tolerant 1002d Yes Yes Yes Fault tolerant 2003 TMR Yes Diverse safety system programmed with Workbench software No NOS Yes Integrated safety system programmed with RSLogix 5000 software Yes fs NY Ho Single project spanning controllers No totes YN 1 The 1002d mechanism for the ControlLogix SIL 2 system is provided by the 1715 1 0 platform A ControlLogix SIL 2 system also provides fault tolerance through controller redundancy but ControlLogix redundancy acts as a hot backup and is not a voting architecture ControlLogix SIL 2 Systems ControlLogix supports process safety applications up to SIL 2 requiring fault tolerance and redundancy ControlLogix supports 1002d fault tolerance with the 1715 I O system However ControlLogix redundancy does not use a voting mechanism rather it acts as a hot standby The components of the 1715 I O system comprise a pair of partnered Ethernet adapter modules that communicate to ControlLogix controllers via an EtherNet IP network and digital and analog I O modules that are configurable in simplex and duplex modes The ControlLogix L7x controller complies with the requirements of the relevant standards SIL2 according to IEC 61508 and can be used in low demand applications up to SIL2 according to IE
55. edundant controllers The ControlNet network supports redundant media and adapters For more information see Network Topologies on page 14 PASS servers can be configured as redundant for the following software components e HMI server e Alarm amp Event server e Data server The AppServ Batch server supports different levels of fault tolerance For more information see Batch High Availability Options on page 35 The PlantPAx system supports off the shelf hardware high availability options for servers from our Encompass partner Marathon Technologies or through virtualization by using VMWare s ESXi architecture ControlLogix controllers support enhanced redundancy on EtherNet IP or ControlNet networks For more information see Redundant Controller Hardware Requirements on page 41 The 1715 redundant I O system offers redundant digital and analog I O modules on EtherNet IP or ControlNet networks For more information see Redundant I O on page 44 Redundant process network interfaces are available for FOUNDATION Fieldbus and PROFIBUS PA networks For more information see FOUNDATION Fieldbus Devices on page 49 and PROFIBUS PA Devices on page 50 See the PlantPAx Reference Manual publication PROCES RM001 for additional redundant components and features such as alarms and events Rockwell Automation Publication PROCES SG001G EN P September 2014 11 Select a PlantPAx System PlantPAx System Estimator Rockwell Autom
56. equires more than one server acquaint yourself with the following descriptions of the data HMI and alarm servers See page 20 for illustrations Software Components Factorylalk Network Directory FID server Factorylalk View HMI server Factorylalk View Data server Factorylalk View Alarms and Events server Description Secures information from multiple Rockwell Automation software components across multiple computers and allows central administration throughout the PlantPAx system In this way application components such as display and security settings can be stored in their original environments and made available to the entire PlantPAx system without the need for duplication See Process Automation System Server Software and Licenses on page 22 for licensing information The human machine interface HMI server is configured within your FactoryTalk View Site Edition SE application The HMI server stores HMI project components such as graphic displays and serves these components to OWSs upon request The HMI server also can manage tag databases and log historical data Multiple HMI servers can exist on the PlantPAx system The Data server component provides access to information from the process controllers to servers and workstations on the PlantPAx system Factorylalk View software supports two types of data servers Rockwell Automation Device servers RSLinx Enterprise software and OPC Data servers The Data server ment
57. es FactoryTalk Batch software eProcedure software and Material Manager software You need a batch server when any of the following apply for your system e Equipment allocation and arbitration e Complex recipes product recipes with loops branches and transitions phases with more than four inputs and four outputs e Multiple unit coordination product is made across multiple coordinated units e More than 32 recipes e String values or numeration required for parameter and report values e Number of parameters or report values required by phase gt 4 e Require class based recipes e Manual and electronic work instructions web based instructions embedded pictures video e Material management materials containers lots locations and inventory tracking Table 19 1 AppServ Batch Virtual Requirements Category Requirement Virtual infrastructure Required e 2vCPU e AGBvRAM min Recommended CPU and memory allocation e Normal priority Resource pool Recommended hard drive sizing averages e 10 input output operations per second IOPS e 3 reads sec e 7 writes sec Operating system Windows 2008 R2 SP1 operating system 64 bit Additional third party software Antivirus software All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation 1 2 See the PlantPAx Reference Manual publication PROCES RM001 for Resource Pool Allocation 3 Check with
58. ess Automation System Servers PASS Operator Workstations OWS Engineering Workstations EWS Application Server HMI AppServ HMI Application Server Information Management AppServ Info Application Server Asset Management AppServ Asset Application Server Batch AppServ Batch Application Server Operator Workstation AppServ OWS Virtual Sizing Example vCPU Physical Core vCPU vRAM 4 GB 2 GB oN G w 4 GB 4 GB 4 GB oN G w 8 GB as ees a ee ee ea es This section provides an example of a virtual sizing calculation that uses figures in Table 22 Table 22 Sample System Information System Components Process Automation System Servers PASS Operator Workstations OWS Engineering Workstations EWS Application Server HMI AppServ HMI Application Server Information Management AppServ Info Application Server Asset Management AppServ Asset Application Server Batch AppServ Batch VMWare View Server based on 3 ESXi servers vCenter Server based on 3 ESXi servers No of Each Component Total vCPU Total Rockwell Automation Publication PROCES SG001G EN P September 2014 in combination Total vRAM 71GB 37 Select a PlantPAx System Customer X requires a runtime memory resource pool of 79 GB to make sure that all virtual machines have sufficient resources as shown in Table 22 Calculate the runtime CPU resource pool requirements System Element No of Physical Cores EWS
59. et IP Network 1788 EN2FFR ControlNet Network _ Linking Device 1788 EN2FFR Linking Devices 1788 CN2FFR Linking Devices p 6 4 1788 FBJB4R Junction Boxes 1788 FBJB4R Junction Boxes FF Field Devices FF Field Devices ii FF Field Devices Table 35 FOUNDATION Fieldbus Interface EtherNet IP interface 1788 EN2FFR Bridge from an Ethernet network to an H1 network Supports redundant media and DLR capable Ethernet network Linking devices have built in termination ControlNet interface 1788 CN2FFR Bridge from a ControlNet network to an H1 network compatible with ControlLogix redundancy and redundant ControlNet media Linking devices have built in termination FOUNDATION Fieldbus network components Both linking devices have built in power conditioning 1788 FBJB4R Intelligent junction box supports redundancy includes four drop ports and four trunk ports 1788 FBJB6 Intelligent junction box with six drop ports and two trunk ports Additional components Pepperl Fuchs FOUNDATION Fieldbus components such as valve couplers surge protectors and distributors See the Encompass website for Pepperl Fuchs product offerings Segment protection Protects against device or line faults with short and open circuit protection Pepperl Fuchs intrinsic safety components such as isolated barrier systems hazardous area enclosures and equipment See the Encompass website for Pepperl Fuchs product offerings FOUNDATION Fiel
60. for OWS upon request e Alarm server When the PASS is used as a data server it is also typically used as an alarm server One HMI server license is required This option contains all of the software components in one server as shown in Option 1 plus an additional server for extra data and alarm capacity without adding an additional HMI server Ifthe PASS server is being used as a data server and additional capacity is needed you can add more PASS servers Use the PSE to determine if more PASS servers are needed A PASS server can typically handle 1 8 controllers We recommend that you have an HMI server on the PASS if you are segregating the application into individual operational areas See Option 3 One HMI server license is required This option lets you configure separate areas each one with its own server that is based on the particular process An HMI server license is required for each PASS You can place the FTD on its own server to manage applications that exist on multiple client servers If an area needs to be shutdown the other separate areas are not affected because the FTD is on its own server For example you can perform maintenance on one area without affecting another operational area of the plant FTD can be a workstation class machine An HMI server license is required for each PASS containing an HMI server Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System
61. hitectures e High Availability Options e PlantPAx System Estimator e Software Release Information This section provides an overview on the system elements and architectures that comprise the PlantPAx system Process System Elements To get started building your system Table 2 summarizes the system elements These elements combinations of hardware and software products are explained throughout this guide with corresponding catalog numbers to assist you with your equipment procurement Table 2 System Element Descriptions System Element Process Automation System Server PASS Operator workstation OWS Engineering workstation EWS AppServ Asset management AppServ Batch AppServ Information management AppServ Historian AppServ OWS Controller Independent workstation IndWS Rockwell Automation Publication PROCES SG001G EN P September 2014 Description The PASS is a required system element that can host displays alarms and data connections to controllers Multiple PASS servers can be used to provide additional system capacity or to create logical segregation of application content based on the process See page 20 for guidance on how many PASS servers you need The OWS provides an interactive graphical interface to monitor and control the process The EWS provides a central location for configuring the system and monitoring maintaining system operation The asset management server acts as a centralized
62. hosted by the PASS server If the PASS server is not being used as an HMI server then no license purchase is required Make sure to account for process displays faceplates navigation devices and so forth in your display count For example the Rockwell Automation Library of Process Objects includes more than 100 faceplates help displays and quick displays If all of the library objects are loaded into your application these faceplates and help files count against your display count license Table 9 3 Process Automation System Server Software and Licenses Virtual image template One copy per project if using virtualization and USB device contains a virtual image template that has pre installed all applications that are virtual image templates required on the PASS 9528 PAXVTENE Rockwell Automation software licenses Select one of the ening per PASS when the PASS Number of displays is used as an HMI server 9528 PASSIOOENE 100 display license for the PASS server 9528 PASS250ENE e 250 display license for the PASS server 9528 PASSUNLENE e Unlimited display license for the PASS server 1 These PASS software licenses are equivalent to Factorylalk View SE server licenses 9701 VWSSOOOLENE 9701 VWSS250LENE 9701 VWSS100LENE You can use either the PlantPAx or Factorylalk View SE software license with the PASS server 22 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Eng
63. ineering 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 You are limited to five EWS per system Table 10 1 EWS Virtual Requirements Category Requirement Virtual infrastructure Required e 2vCPU e 4GBvRAM min Recommended CPU and memory allocation Normal priority Resource pool Recommended hard drive sizing averages e 30 input output operations per second IOPS e 24 reads sec e 6 writes sec Operating system Windows 7 Professional SP1 operating system 64 bit Additional third party software Antivirus software 1 2 3 4 All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation See the PlantPAx Reference Manual publication PROCES RMQ01 for Resource Pool Allocation Check with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at https www rockwellautomation custhelp com _ Table 10 2 EWS Traditional Requirements Category Requirement Traditional infrastructure The EWS must be installed on workstation class hardware The following are sample specifications based on PlantP
64. ing g Sees aaan aa I eses EEEE E EECEEE mena o aae n aaa cee Eer El EEEE E EEE m E E J 9 D e C A TES i m 1 Not characterized with the PlantPAx system but a valid configuration Select a PlantPAx System Description A redundant star topology is essentially where every Layer 2 access switch has dual connections to a Layer 3 distribution switch Devices are connected to the Layer 2 switches Advantages Disadvantages Resiliency from multiple connection failures e Additional wiring and ports required Faster convergence to connection loss e Additional configuration complexity Consistent number of hops provide predictable and consistent performance Fewer congestion problems A switch ring network is a single fault tolerant ring network that connects Layer 2 switches to a Layer 3 distribution switch Advantages Disadvantages e Ability to survive a single point of failure or a e Additional configuration complexity device being powered down on the ring Longer convergence times Simplified cabling Variable number of hops can make performance e Ability to cover long distances by using fiber difficult to predict Additional Ethernet features that support high availability include these advanced network resiliency and convergence techniques e EtherChannel and Link
65. ioned in PlantPAx documentation generally refers to the Rockwell Automation Device servers Data servers are configured within your FactoryTalk View SE application Multiple data servers can exist on the PlantPAx system The Alarms and Events server publishes information from controllers and servers available to all subscribing OWSs Alarms and Events servers are configured within your FactoryTalk View SE application There are two types of Alarms and Events servers device based and server based Device based Alarms and Events servers are configured as an option to the data server The Server based Alarms and Events servers are configured as a separate component The Alarms and Events server mentioned in PlantPAx documentation refers to the Alarms and Events server that is server based 1 In redundant PASS configurations this component is included on the primary PASS only See PASS Redundancy Options on page 21 for more information Rockwell Automation Publication PROCES SG001G EN P September 2014 19 Select a PlantPAx System Determining the Number of PASS Servers The following graphics illustrate how many servers are needed when you are not considering redundancy options If you are using redundant servers see page 21 Server Options Option 1 One Server FTD Data server HMI server Alarm server Option 2 One Server with Additional Data Capacity Required
66. mber 2014 Select a PlantPAx System Table 46 Diverse SIL 2 and SIL 3 Products Category Description AADvance system The AADvance technology is the following e Configurable for SIL 2 and SIL 3 e Scalable redundancy for fault tolerance e Simplex duplex or triplex configuration Trusted system Trusted technology uses 3 2 0 3 2 2 0 optionally 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 Table 47 Additional Resources Resource Description AADvance Solutions Handbook publication ICSTI RM447 Explains the features performance and functionality of the AADvance controller and systems It sets out some guidelines on how to specify a system to meet your application requirements AADvance System Build Manual publication ICSTI RM448 Provides experienced panel builders with information on how to assemble a system switch on and validate the operation of a controller AADvance Configuration Guide publication ICSTT RM405 Defines how to configure an AADvance controller by using the AADvance Workbench to meet your Safety Instrument Function SIF application requirements AADvance Safety Manual publication CST T RM446 Defines mandatory standards and makes recommendations to safely apply AADvance controllers for a SIF application Explains how to use tradition al and extreme environment ControlLogix con
67. mic MPC 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 helps improve process performance Use the Pavilion platform within a PlantPAx system to add model predictive control environmental performance management and production performance management For purchase information contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication PROCES SG001G EN P September 2014 57 Select a PlantPAx System Notes 58 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Process Safety Systems A process safety system includes specifically engineered Select from the following options hardware and software controls that are designed to perform e ControlLogix SIL 2 Systems specific control functions to fail safe or maintain safe operation of a process when unacceptable or dangerous conditions occur Process safety systems also are referred to as Safety Instrumented Systems SIS e AADvance and Trusted SIL2 SIL3 and TMR systems e GuardLogix SIL 3 Systems e Sil rated Instruments e PowerFlex SIL 2 and SIL 3 Systems Basic Process Control System Safety Instrumented Systems SIS SIL 0 SIL 1 SIL 2 SIL 2 SIL 3 SIL 3 Process Fail Safe Fail Safe Fault Tolerant Fail Safe Fault Tolerant Pla
68. multivariable control MMC Controls two process variables with up to three control variables It is good for situations where there is significant interaction between the various control variables and process variables Table 42 APC Software Category Cat No Description Automation software e 9324 RLDAPCENE for first controller RSLogix 5000 APC Design License e 9324 RLDAPCCLENE for subsequent controllers RSLogix 5000 APC Run time License 1 Different languages are available but you must contact your local Allen Bradley distributor or Rockwell Automation sales representative Fuzzy Designer Fuzzy logic is useful when a well tuned PID controller does not provide desired response but an expert knows from experience how to modify controller settings on the fly Fuzzy Designer software lets you do the following e Convert expert know how into a control solution e Generate an Add On Instruction for Logix5000 applications Table 43 Fuzzy Designer Software Category Cat No Description Automation software 9324 RLDFZYENE e Fuzzy Designer for RSLogix 5000 software 1 English version is listed Different languages are available by contacting your local Allen Bradley distributor or Rockwell Automation sales representative 56 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Soft Sensors Soft sensors built with PlantPAx Model Builder software can automatically predict produc
69. n Explains the infrastructure components that allow this open network to communicate seamlessly throughout a plant from shop floor to top floor Provides information on Rockwell Automation 1585 Ethernet cables Provides information on Ethernet security and firewalls Website helps you find product related downloads including firmware release notes associated software drivers tools and utilities Explains how to select a distributed 1 0 system for safe and hazardous environments Explains how to select modular I O modules for your system requirements Explains how to select ArmorBlock 1 0 blocks that are suitable for On Machine use Explains how to select ArmorPOINT 1 0 modules List of instruments from Endress Hauser Provides information on connected cabling systems and infrastructure management from Encompass partner Panduit Corporation Provides a step by step approach to integrating Endress Hauser devices into a Rockwell Automation Integrated Architecture for Process Control system Complete list of ControlLogix products that are certified for SIL 1 and SIL 2 applications ControlLogix components supported in SIL 2 configurations Explains the features performance and functionality of the AADvance controller and systems It sets out some guidelines on how to specify a system to meet your application requirements Provides experienced panel builders with information on how to assemble a system switch on and validate the
70. nclude impurity percentage moisture content color density and fineness Instead of making direct control outputs supervisory controls generate setpoints for lower level regulatory controls thus good regulatory control performance is an essential first step before implementing supervisory control Rockwell Automation Publication PROCES SG001G EN P September 2014 55 Select a PlantPAx System Regulatory Control Options APC function blocks can be used in place of PID instructions for loops with long dead times and interacting loops The APC function blocks are licensed and run on the EWS and require RSLogix 5000 software Table 41 APC Function Block Descriptions APC Instruction Description Internal model control IMC Controls a single process variable Such as a temperature or pressure with a single control variable such as a valve position Or pump speed Compares actual process error against error calculated by an internal first order lag plus dead time model Suitable for long dead time processes which are difficult to control with standard PID loops Coordinated control CC Controls a single process variable with up to three control variables It is good for situations where multiple outputs are available for control and costs need to be minimized or for situations where additional process information is available for feed forward control Target values and priorities for outputs are used to optimize your process Modular
71. nits 34 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Batch High Availability Options Batch high availability options depend on the hardware and software options in the system For the application server in a system where a bump in the process cannot be tolerated FactoryTalk Batch software helps support a real time uninterrupted high availability option that leverages Stratix servers or VMWare virtualization Standard FactoryTalk Batch software supports a warm back up option that allows a Batch server to startup and rebuild the active batches from the Event Journals and Logs and places them on the batch list in a held state The primary server copies real time data to the back up server On failure the process goes to a controlled state On restart of the back up server you clear the failure and the process resumes where it left off A redundant ControlLogix system with PhaseManager software provides protection so that the control platform continues to execute during a hardware failure If your system requirements include the batch not going to hold on a controller switchover the connection bridge 1756 CN2R module between the component and a redundant chassis on the ControlNet network needs to be paired with a 1756 EN2TR bridge module to the EtherNet IP network If batch hold upon a controller switchover is acceptable you can connect to the FactoryTalk Batch server directly from an
72. not activated A Microsoft full packaged product license is included 9528 APPOWSENE USB device that contains the virtual image template for AppServ OWS The template contains a Microsoft Windows operating system with all required Rockwell Automation software pre installed but not activated A Microsoft full packaged product license is included IMPORTANT Each client connecting to APPServ OWS must have a valid client license 9528 APPHISTENE USB device that contains the virtual image template for AppServ Hist The template contains a Microsoft Windows operating system with all required Rockwell Automation software pre installed but not activated A Microsoft full packaged product license is included Traditional Infrastructure In a traditional infrastructure each server and workstation is installed on its own physical machine Software and hardware installations on individual computers require more time and maintenance than virtualized machines In addition system backups are more complicated and time consuming than with a virtual environment Thus having the ability to run multiple VMs on one physical computer enhances the optimization of server and workstation physical assets Network Topologies Industrial Ethernet systems require various infrastructure components to connect all the segments together These include hubs switches especially managed switches media converters cables and routers It is recommended that managed s
73. ntPAx Logix T GuardLogix Ti AADvance Scalable Safety Tai N EtherNet IP Communication AADvance and PlantPAx i Trusted TMR Safe reliable systems safeguard people property the environment and reputations Safety Integrity Level SIL certification makes it simpler easier and less expensive to meet growing standards compliance requirements worldwide Select a process safety system based on required SIL level and project requirements For example if your process is designed to always fail safely upon a fault you can select a fail safe only system If you want some level of fault tolerance for your process safety system you can select a fault tolerant system There are different levels of fault tolerance available For example e 1002d refers to a voting architecture where oo means out of as in one out of two 1002 signal state changes is required to detect a system failure Diagnostics are used to reject component failures e 2003 refers to a voting architecture where two out of three 2003 signal state changes are required to detect a system failure This lets a failed signal to be ignored in addition to rejection of component failures This architecture also is referred to as Triple Modular Redundancy TMR Rockwell Automation Publication PROCES SG001G EN P September 2014 59 Select a PlantPAx System Table 45 shows the capabilities of the process safety systems Your solution can includ
74. ntinuous process and batch applications including Advanced Process Control functions These controllers also support discrete and motion applications The independent workstation serves as a PASS EWS and OWS for single station systems independent class Select a PlantPAx System PlantPAx System Architectures Rockwell Automation characterizes the PlantPAx system based on its size or architecture class A characterized system tested classification yields system performance data and recommended hardware and software configurations The classes of PlantPAx architecture offer system scalability while organizing Integrated Architecture products consistent with process industry expectations The architecture classes shown below include the following e System architecture with single station acting as PASS OWS and EWS e Distributed system architecture for single server with multiple OWS and EWS e Distributed system architecture for multiple servers and multiple OWS and EWS Distributed Architecture Multiple PASS Servers Distributed Architecture Single PASS Server g er EREE E _ a WI Wt f i cane oS Station Architecture 3 A eo 33 i me I
75. o are capacity limited This can be roughly estimated based on I O count but also is greatly impacted by the design of your application These limitations can include the amount of automation code required the amount of information being read by supervisory applications and the number of alarms in your system Controller Sizing The I O count for controller sizing is often determined directly from the application P amp ID or plant design On existing systems where classic I O is used only for example 4 20 mA 24V DC dry contacts and so forth the I O count can be determined by the number of I O channels available on the I O cards When you have integrated smart devices such as drives on transmitters on an EtherNet IP network any signal from the device used by your control strategy is considered an I O point But be careful when sizing traditional I O and Ethernet I O because from a sizing perspective there is a load difference For example an I O count for a system comprised with the following e Two 8 channel 4 20 mA input cards e One 8 channel 4 20 mA output cards e Two 16 channel 24V DC dry contact input cards e One MCC with six drives Each drive provides six signals to the control strategy speed reference actual speed start stop running and fault e Two Coriolis meters on PROFIBUS PA with each meter providing three signals for flow temperature and density The I O count example has the following calculation 4 20 m
76. ocess data on a remote computer to minimize the amount of information on a network The AppServ OWS is only configured to run FactoryTalk View SE clients and the recommended limit is 10 clients per application server Table 12 1 AppServ OWS Virtual Requirements Category Requirement Virtual infrastructure Required e AvCPU e 8 amp GBvRAM min Recommended CPU and memory allocation e Normal priority Resource pool Recommended hard drive sizing averages e 40 input output operations per second IOP e 25 reads sec e 5 writes sec Operating system Windows 2008 R2 SP1 operating system 64 bit Thin client We recommend a maximum of 10 FactoryTalk View SE clients per application server Additional third party software Microsoft Internet Explorer Antivirus software All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation 1 2 See the PlantPAx Reference Manual publication PROCES RM001 for Resource Pool Allocation 3 Check with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed 4 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 12 2 AppServ OWS Automation System Software and License Virtual image template One per project if using virtualization and virtual USB
77. onfigure and implement e Loss of network service in case of a connection Direct path between the infrastructure device failure of a single component and the end device e Primarily the single point of failure of the Remove and add devices without affecting the centralized switch rest of the network Centralization can ease troubleshooting because the switch sees the activities of all of the connected devices A ControlNet network supports the option of redundant media For information on ControlNet media see ControlNet Media System Components List AG PA002 Advantages Disadvantages ControlNet network supports a variety of e An additional network topology cabling and topologies including trunkline dropline star components for adding devices to the network tree and ring e New 1 0 modules are to be scheduled Deterministic real time control network that provides high speed transport of both time critical 1 0 and messaging data e No isolation for short circuits in comparison to Ethernet network Network unaffected by devices being connected or disconnected from the network 16 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Domain Controller A domain controller is a server that responds to security authentication requests logging in checking permissions and so forth within the Windows server domain A domain grants you access to a number of network resources such as
78. or logging e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Antivirus software Rockwell Automation Publication PROCES SG001G EN P September 2014 31 Select a PlantPAx System Table 18 3 AppServ Asset Server Software and Licenses Category Cat No Description Asset Management software The following is required to include any option below 9515 ASTSRVRENE Factorylalk AssetCentre server Add on capabilities Select one or more of the following so that the sum of licenses is equal to or greater than the number of assets that is to be managed by the Asset Management server 9515 ASTCAPOO05E e 5 additional assets 9515 ASTCAPOO25E e 25 additional assets 9515 ASTCAPO100E e 100 additional assets 95 15 ASTCAPOSO0E e 500 additional assets 9515 ASTCAP 1000E e 1000 additional assets 9515 ASTCAPSO00E e 5000 additional assets If process device configuration is to be used select the following 9515 ASTPRDCFENE FactoryTalk AssetCentre process device configuration If disaster recovery is to be used select all of the following e 9515 ASTDRROKENE e Disaster recovery for Rockwell Automation 9515 ASTDRRCENE e Disaster recovery for remote computers If calibration management is to be used the first license is required and the remainder
79. or specifics Manufacturers provide drives with varying amount of capacity at each speed 4 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 16 2 AppServ Info Historian Traditional Requirements Category Requirement Traditional infrastructure The Information Management server must be installed on server class hardware e Intel Xeon Multicore processor 4 cores or greater e 2 40 GHz CPU e 4GBRAM min e Dual hard drives one for application code one for logging e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 2008 R2 SP1 operating system 64 bit includes Microsoft Internet IIS with WWW service Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 16 3 AppServ Info Historian Software Category Requirement Description Virtual image template One per project if using virtualization and virtual USB device contains a virtual template for the AppServ Hist image templates 9528 APPHISTENE 28 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Table 16 4
80. ort EtherNet IP option module e PROFIBUS DPV1 option module e Single port PROFINET 1 0 option module Dual port PROFINET 1 0 option module ControlNet communication adapter coax e DeviceNet communication adapter EtherNet IP communication adapter e HVAC communication adapter only Modbus RTU CANopen communication adapter LonWorks communication adapter e Modbus TCP communication adapter e PROFIBUS DR communication adapter ControlNet communication adapter fiber e Remote 0 communication adapter e RS485 DF1 communication adapter 2 Requires a Communication Carrier Card 20 750 20COMM or 20 750 COMM F1 Refer to the PowerFlex 750 series Technical Data publication 750 1D001 for details 3 This item has Silver Series status Rockwell Automation Publication PROCES SG001G EN P September 2014 51 Select a PlantPAx System Soft Starters SMC Soft Starters are designed to help minimize cost by reducing overall system power requirements and wear and tear on equipment Our soft starters can be easily integrated into your process control system to offer higher productivity and shorter downtimes We offer a diverse line of soft starters to meet your communication control and space requirements Table 38 SMC Soft Starters and Communication Modules Cat No Description 150 F SMC Flex Smart Motor Controllers 150 5 SMC 50 Solid State Smart Motor Controllers ControlLogix L 7x
81. rating system 64 bit Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 13 2 IndWS Automation System Software and Licenses PlantPAx software One per IndWS if being used as EWS RSLogix 5000 Professional Edition software 9324 RLD O0NXENE Rockwell Automation software licenses Select one of the following Number of displays 9701 VWSBI100ENE e 100 display license with FactoryTalk View SE network station 9701 VWSB250ENE e 250 display license with FactoryTalk View SE network station 9701 VWSBOOOAENE e Unlimited display license with FactoryTalk View SE network station 26 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Information Management Application Server AppServ Info Information management application servers AppServ Info represent a broad category of servers and software that provide value to the PlantPAx system offering data management and decision support functionality This section outlines various options available to meet the needs of your system Except where specifically noted all of the options listed below must be installed on their own servers to maximize performance While it is possible to install data management Table 14 and decision support lable 15 software on the same
82. rements by the minimum number of servers required to run the system at any given time For example with a three server system using VMware fault tolerance or high availability you divide by two to make sure that the system can continue to run with two servers if one server fails VMware Sizing Virtual Machines are always limited by the megahertz capability of the physical core A common misconception is that a VM can utilize as much CPU megahertz as needed from the combined total available A single vCPU VM can never use more megahertz then the maximum of one CPU core If a VM has 2 vCPUs it can never use more megahertz than the maximum of each CPU core 36 Rockwell Automation Publication PROCES SG001G EN P September 2014 Determine the number of physical cores required for a system by using the consolidation ratios in Table 21 1 Select a PlantPAx System with the vCPU requirements documented in Table 21 2 for a PlantPAx system with a known architecture Table 21 1 CPU Consolidation Ratios Server and Workstation Type Process Automation System Servers PASS Operator Workstations OWS Engineering Workstations EWS Application Server HMI AppServ HMI Application Server Information Management AppServ Info Application Server Asset Management AppServ Asset Application Server Batch AppServ Batch VMware VCenter VMware View Server Table 21 2 PlantPAx Resource Requirements PlantPAx System Elements x64 bit 0S Proc
83. rload Relays See communication modules on page 53 E3 Plus Electronic Overload Relays E300 Electronic Overload Relays Motor control centers CENTERLINE 2100 e Built in EtherNet IP connectivity or via 1788 EN2DN linking device CENTERLINE 2500 e Built in DeviceNet connectivity e ControlNet connectivity via 1788 CN2DN linking device Condition monitoring 1440 XM intelligent I O modules e Built in DeviceNet connectivity e ControlNet connectivity via 1440 ACNR ControlNet adapter with 1440 DYN02 01RJ module only 1 lfenvironmental conditions warrant you can use extreme temperature FLEX 1 0 modules 2 fenvironmental conditions warrant you can use extreme temperature ControlLogix modules 3 Networked motor control center devices can be used in place of standard 1 0 modules digital and analog outputs Redundant I O The 1715 redundant I O system lets a ControlLogix controller communicate to a remote redundant I O chassis over an EtherNet IP network The 1715 redundant I O system provides fault tolerance and redundancy for critical processes by using a redundant adapter pair and multiple I O modules that have enhanced diagnostics Crossload Media ControlLogix Primary Chassis ControlLogix Secondary Chassis i 0 E a J uw EtherNet IP Device level Ring eee sesse ma re E JE l i a a a fala 1715 Redundant 1 0 Syste
84. rtfolio for APC provides a comprehensive set of tools and solutions to optimize performance This scalable framework lets you add the tools you need e Control regulatory loops individual process units and plant operations e Use modeling techniques to achieve more accurate and robust models Pavilion8 Software Model Builder Software APC Function Blocks and Fuzzy Designer Model Predictive Control Software and Real Time Optimization Standard Logix5000 Inferential Sensor Instructions Advanced Regulatory Regulatory Control Control As you add advanced process control technologies the technologies deliver more value while becoming more complex There are two main categories for APC technologies regulatory control and supervisory control e Regulatory control focuses on the process variables levels flows temperatures pressures and so forth and is designed to improve poorly performing loops and automate loops that are typically run in manual by the operator They include techniques such as ratio feed forward cascade and decoupling control and can be used to compensate for process dead time and simple process coupling and nonlinearities that a PID loop cannot handle e Supervisory control focuses on the product being manufactured cement polyethylene ethanol paper and so forth and is designed to control the various product specifications and parameters that determine whether the product is marketable Parameters i
85. s select one for each CPU of the hosting server 9521 VPCPPENE Select the following e 9521 VPHSCENE 9521 VPRICENE Factorylalk VantagePoint EMI server software e 1 named user e 3named users e 5named users e 10 named users e 25 named users e 50 named users e 1 concurrent user e 3 concurrent users e 5 concurrent users e 10 concurrent users e 25 concurrent users e 50 concurrent users Factorylalk VantagePoint Concurrent User CPU License per CPU e Factorylalk VantagePoint 3rd Party Historian Connector e Factorylalk VantagePoint 3rd Party Real time Connector 1 English version is listed Different languages are available by contacting your local Allen Bradley distributor or Rockwell Automation sales representative 30 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Asset Management Server AppServ Asset An asset management server AppServ Asset is an extension to the PlantPAx system that adds maintenance and plant operations to the system This server provides disaster recovery controller data diagnostics calibration real time monitoring as well as auditing equipment and network health to improve overall resource availability The asset management server provides a centralized system management for end field devices Table 18 1 AppServ Asset Virtual Requirements Category Virtual infrastructure Operating system Additional third party software
86. s supported by ODVA Fieldbus or fur In a PlantPAx system the ControlNet network supports PROFIBUS PA HART Devices controller downlinks and connections to remote I O and field Network device interface Table 32 ControlNet Interface ControlLogix controller interface 1756 CN2 1756 CN2R ControlLogix ControlNet scanner 1756 CNB 1756 CNBR 1788 CN2FFR ControlNet to FOUNDATION Fieldbus linking device Supports H1 FOUNDATION Fieldbus networks Compatible with ControlLogix redundancy and redundant ControlNet media 1788 CN2PAR ControlNet to PROFIBUS PA linking device Supports redundant PROFIBUS PA media and redundant ControlNet media DeviceNet Devices The DeviceNet network is an open device level network that provides connections between simple industrial devices such as sensors and actuators and higher level devices such as PLC controllers and computers The DeviceNet network uses the proven CENTERLINE Common Industrial Protocol CIP to provide the control Motor Control configuration and data collection capabilities for industrial devices PowerFlex Center DeviceNet is supported by ODVA Drives L ma In a PlantPAx system the DeviceNet network connects networked control devices jes Table 33 DeviceNet Interface ControlLogix controller interface 1756 DNB ControlLogix DeviceNet scanner Rockwell Automation Publication PROCES SG001G EN P September 2014 47 Select a PlantPAx System
87. server for small scale applications we do not recommend doing so Data management solutions can contain chassis based and server based historian systems Table 14 Data Management Options Time series High speed On Machine data collection e lt 2500 tags e Longer term data storage e gt 2500 tags Event based Relational database 1 For more information see Knowledgebase Answer ID 48313 at http www rockwellautomation custhelp com Information Management server is optional because you can use an embedded historian module for the ControlLogix chassis FactoryTalk Historian Machine Edition If the historian ME module is collecting 2500 points per second select one of the following depending on how long it takes for the onboard memory to become full e 1756 HIST1G 1 GB 4 hours e 1756 HIST2G 2 GB 14 hours Factorylalk Historian ME also can be accessed directly by various decision support tools FactoryTalk VantagePoint ProcessBook and TrendX View SE software version 7 0 and later Factorylalk Historian ME is compatible with Factorylalk Historian Site Edition software which lets the module offload and forward that data In the event that no Historian Site Edition server is provided the Continuous data buffer can be configured to overwrite oldest data or stop data collection when it reaches storage capacity An Information Management server is required with FactoryTalk Historian SE software which is a scala
88. standard embedded feature with a safety rating of PLd SIL2 Cat 3 The PowerFlex 753 and 755 AC drives are available with optional STO functionality with a safety rating of PLe SIL3 Cat 3 In addition the PowerFlex 753 and 755 offer a Safe Soeed Monitor option for applications that can benefit from access to a safety zone while there is limited motion The Safe Soeed Monitor option has a rating of PLe SIL3 Cat 4 PowerFlex STO functionality is designed to help safely remove power from the gate firing circuits of the drive s output power devices IGBT s This helps prevent the drive s output power devices from switching in the pattern necessary to generate AC power to the motor Can be used in combination with other safety devices to satisfy the requirements of IEC 61508 IEC 61800 5 2 SIL 3 ISO 13849 1 PL e and Category 3 for STO For more information see the PowerFlex Low Voltage AC Drives Selection Guide publication PFLEX SG002 62 Rockwell Automation Publication PROCES SG001G EN P September 2014 AADvance ArcShield Allen Bradley ArmorBlock ArmorPOINT CENTERLINE Compact I O CompactBlock CompactLogix ControlLogix Encompass E1 Plus E3 Plus E300 eProcedure FactoryTalk FLEX FLEX Ex GuardLogix Integrated Architecture IntelliCENTER LISTEN THINK SOLVE Logix5000 On Machine Pavilion8 PhaseManager PlantPAx POINT I O PowerFlex Rockwell Automation Rockwell Software RSBizware RSLinx RSLogix Secure Connect SMC Sof
89. t Sensor Stratix 5700 Stratix 6000 Stratix 8000 Stratix 8300 and XM are trademarks of Rockwell Automation Inc Cisco is a trademark of Cisco Systems Inc ControlNet DeviceNet and EtherNet IP are trademarks of the ODVA Intel is a trademark of the Intel Corporation Microsoft and Windows are trademarks of the Microsoft Corporation Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PROCES SG001G EN P September 2014 Supersedes Publication PROCES SG001F EN P June 2013 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
90. t quality parameters in real time and provide backup or an alternative to analyzers to generate feedback for mission critical control systems The software which runs on the EWS also includes the following e ModelBuilder provides offline data analysis and modeling e SoftSensor Designer converts models to Add On Instructions Table 44 PlantPAx ModelBuilder Software Automation software Select one or more of the following e 9529 PPMDBENE e PlantPAx ModelBuilder e 9529 PPMSBENE e PlantPAx ModelBuilder and SoftSensor Designer e 9529 PPMSSENE e Soft Sensor Designer Supervisory Control Options The most common supervisory control m technique is Model Predictive Control MPC am which can handle large multivariable i j processes and control these product parameters while simultaneously optimizing Console the production process through maximizing rates and yields reducing raw material usage minimizing energy and so forth Soft The Pavilion8 software platform is a leas modular design that includes modules to help control analyze monitor visualize warehouse and integrate information MPC AR fo AN S technology is an intelligence layer on top of A basic automation systems that continuously drives the plant to assist in achieving Eag multiple business objectives cost reductions decreased emissions consistent quality and production increases every production minute Controller Metrics Dyna
91. teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 7 Professional SP1 operating system 64 bit Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com On an OWS you can run multiple screens Each screen impacts the data server and controller loading Table 11 3 OWS Automation System Software and License Virtual image template One per project if using virtualization and virtual USB device contains a virtual image template that has pre installed all applications that are image templates required on the OWS 9528 PAXVTENE Rockwell Automation software license For each OWS Software activation license for the OWS for virtual and traditional environments 9528 OWSLICENE 1 This PlantPAx software license is equivalent to a FactoryTalk View SE Client license 9701 VWSCWAENE You can use either a PlantPAx or FactoryTalk View SE software license with the OWS 24 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Operator Workstation Application Server AppServ OWS The AppServ OWS uses Microsoft Remote Desktop Services RDS technology to serve multiple instances of the OWS as thin clients from a single server Thin clients can run applications and pr
92. tices for developing your application e Develop Specific Application Contains the application specific libraries and objects that are used to construct your application that resides on the PlantPAx architecture Purpose of Selection Guide This PlantPAx Selection Guide is designed to step you through the selection of system elements for creating a bill of materials for ordering your system Using the prescribed architecture and recommendations explained in this manual you can use the PlantPAx System Estimator PSE in a similar fashion to select a system when using the Integrated Architecture Builder IAB software The PSE is part of the IAB tool See page 12 for details You do not need to read the sections in the order outlined on page 3 However we do recommend that you start with the Overview to acquaint yourself with the system elements and architecture that comprise the PlantPAx system 2 Rockwell Automation Publication PROCES SG001G EN P September 2014 Select a PlantPAx System Overview System Architectures Page 7 E PE System Infrastructure BE ees Page 13 Servers and Workstations Page 19 Controllers E I 3 E E J aa Page 39 Field Networks and 1 0 Page 43 Advanced Process Control Page 55 Process Safety Systems Page 59 Review PlantPAx system elements e System architectures
93. tions process http www migratemyprocess com webinars Infrastructure Virtual Image Templates User Manual publication 9528 UM001 PlantPAx Process Automation System Reference Manual publication PROCES RMO01 Description Describes how to configure controller and HMI templates to start development of your PlantPAx system Provides information on PlantPAx system hardware specifications and certifications PlantPAx Knowledgebase Table of Contents Links to Rockwell Automation Library of Process Objects and associated documents for tips and best practices Explains how to use tradition al and extreme environment ControlLogix controllers Explains how to select a ControlLogix system based on your application requirements Explains how to select a CompactLogix system based on your application needs Describes the courses that are available for a better understanding of the PlantPAx system Explains how to install and set up the 1715 Redundant 1 0 system Provides 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 Features prerecorded webinars on the DCS migration program and capabilities for process customers Describes the catalog numbers and details for using virtual image templates for setting up virtual machines Provides characterized recommendations for implementing your PlantPAx system
94. tool for managing automation related asset information both Rockwell Automation and third party assets The asset management application server includes capabilities for source control audits change notifications calibration of instrumentation reporting and security The batch application server provides comprehensive Batch Management including unit supervision recipe management process management and material management The batch application server can be linked with visualization elements at the OWS and configuration clients on the EWS Information management servers store and manage manufacturing data as well as host decision support tools Decision support tools include real time reports trends and dashboards that publish key performance indicators KPIs through a web browser Iwo options for the AppServ Info server include Historian see below and decision support VantagePoint software This base installation of the FactoryTalk Historian server is configured via a virtual template The server collects manages and analyzes real time data from the PlantPAx system The AppServ OWS uses Microsoft Remote Desktop Services RDS technology to serve up to 10 instances of the OWS as thin clients from a single server This provides for FactoryTalk View SE thin clients running applications and processing data on a remote computer to reduce the amount of information on a network The ControlLogix and CompactLogix controllers support co
95. trollers AADvance Troubleshooting and Repair Manual publication ICS TT RM406 Provides plant maintenance personnel with information on how to trace and repair a fault in an AADvance system and perform routine maintenance tasks GuardLogjix SIL 3 Systems GuardLogix supports safety applications up to and including SIL 3 fail safe only applications for simplex controllers The GuardLogix L7x controller complies with the requirements of the relevant standards Cat 4 PL e according to EN ISO 13449 1 SIL CL 3 according to EN 62061 IEC 61508 IEC 61511 EN 50156 1 and can be used in applications up to Cat 4 PL e according to EN ISO 13849 1 and SIL 3 according to EN 62061 IEC 61508 IEC 61511 EN 50156 1 The instructions of the associated Safety Reference Manual and User Manuals are to be considered For more information see the GuardLogix Controllers User Manual publication 1756 UMO20I SIL rated Instruments SlL rated instruments are typically required for process safety loops Rockwell Automation provides premier integration between ControlLogix systems and Endress Hauser SlL rated instruments For more details see the Endress Hauser web site at http www us endress com Rockwell Automation Publication PROCES SG001G EN P September 2014 61 Select a PlantPAx System PowerFlex SIL 2 and SIL 3 Systems PowerFlex AC drives offer SIL ratings up to and including SIL 3 Specifically the PowerFlex 525 AC drive offers Safe Torque Off STO as a
96. upports operator interaction and is not meant to support development or maintenance activities although these activities are possible if desired Table 11 1 OWS Virtual Requirements Category Requirement Virtual infrastructure Required e 1VvCPU e 2GBvRAMmin Recommended CPU and memory allocation e Normal priority Resource pool Recommended hard drive sizing averages e 15 input output operations per second IOPS e 10 reads sec e 5 writes sec Operating system Windows 7 Professional SP1 operating system 64 bit Additional third party software Antivirus software 1 2 3 4 All numbers and figures are referenced for initial sizing only Actual performance can vary in final implementation See the PlantPAx Reference Manual publication PROCES RMO01 for Resource Pool Allocation Check with your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com ee e Table 11 2 OWS Traditional Requirements Category Requirement Traditional infrastructure The OWS must be installed on workstation class hardware The following are sample specifications based on PlantPAx system characterization e Intel Core 2 Duo e 240 GHz CPU e 2GBRAMmin e Ethernet card that supports redundant media if NIC
97. ured operator faceplates that provide visualization of instruments connected to the network interface e Field Device Tool Device Type Manager FDT DTM technology allows access to field device configuration and diagnostics via FDT Frames such as FactoryTalk AssetCentre In addition the Rockwell Automation FDT ThinFrame read only can be launched via the Add On Profile providing access to each field device status and extended diagnostics 50 Rockwell Automation Publication PROCES SG001G EN P September 2014 Field Devices Rockwell Automation offers a broad range of motor control solutions to complement a variety of application requirements The portfolio of motor control includes more simplified programming and configuration along with safety features to protect personnel and assets that helps to reduce downtime Drives PowerFlex Low Voltage AC drives provide scalable motor control solutions and are designed to deliver more powerful performance and flexibility for process applications As part of a PlantPAx system PowerFlex drives offer seamless integration into your process control system for simplified development use and maintenance The benefits of this exceptional level of integration between the drives and Logix controllers provides distinctive time saving features for the PowerFlex 525 753 and 755 drives including Automatic Device Configuration ControlLogix L 7x lc if E
98. witches be used throughout Managed switches can be configured in several topologies For more information on switches see page 18 Table 6 Supervisory Network Topology Description Star The traditional most common EtherNet IP network topology is a star where end devices are connected and communicate with each other via a switch In a star topology nodes are typically grouped closely together Advantages Disadvantages Easy to design configure and implement e Loss of network service in case of a connection failure of a single component Direct path between the infrastructure device and the end device e Primarily the single point of failure of the centralized switch Remove and add devices without affecting the rest of the network Increase port capacity on the switch to add more devices Centralization can ease troubleshooting because the switch sees the activities of all of the connected devices 14 Rockwell Automation Publication PROCES SG001G EN P September 2014 Table 6 Supervisory Network Topology Redundant Star Dl a Jae me NN Switch r
99. your drive manufacturer for specifics Manufacturers provide drives with varying amount of capacity at each speed 4 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Table 19 2 AppServ Batch Traditional Requirements Category Requirement Traditional infrastructure The Batch Management server must be installed on server class hardware e Intel Xeon Multicore processor 4 cores or greater e 2 40 GHz CPU e 4GB RAM min e Dual hard drives one for application code one for logging e Ethernet card that supports redundant media if NIC teaming is used If you plan to use a motherboard NIC make sure it supports redundant media Operating system Windows 2008 R2 SP1 operating system 64 bit Additional third party software Antivirus software 1 Rockwell Automation has tested the use of Symantec Endpoint Protection For more information see Knowledgebase Answer ID 35330 at http www rockwellautomation custhelp com Rockwell Automation Publication PROCES SG001G EN P September 2014 33 Select a PlantPAx System Table 19 3 Batch Management Server Licenses Batch licenses Purchase multiple licenses to obtain the desired number of batch units For example purchase 3 licenses if you have 100 units on a single batch unit 1 license with 10 units 1 license for 30 units and 1 license for 60 units 9358 FIBOTENE e

proces-sg001 - Literature Library

Contents

Download Pdf Manuals

Related Search

Related Contents