Ab Plant Pax

Selection Guide
PlantPAx Process Automation System

System Release 2.0
Selection Guide Scope
The PlantPAx Process Automation System is a defined set of standard Rockwell

Automation Integrated Architecture products that are configured in a prescribed way to
provide optimal performance as a process automation system. When combining PlantPAx
core system components, tools, and utilities, with other Rockwell Automation and partners
products, the result is unmatched automation system flexibility, scalability, and
expandability when solving continuous batch as well as high-speed discrete applications.
This PlantPAx Selection Guide is used to assist with equipment procurement after you have
defined your system requirements.
Figure 1 - Selection Guide Scope
Define
&
Procure
System
Setup &
C
Configuration
n
Application
Specific
Code
System
Test
CCommissionn
Support
PlantPAx System Overview

Core System Definition
Field Device Integration
Batch Management
Process Information
Advanced Process
High Availability
Critical Process
Infrastructure
Migration
32238-MC
Selection Guide
You do not need to read the sections in sequential chapter order. If you already have selected
core elementsfor example, defining the computer hardware and operating systemyou
can skip to other sections, such as PlantPAx infrastructure requirements or the types of
process instrumentation on your network.
You can view or download publications at
http://www.rockwellautomation.com/literature. To order paper copies of technical
documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Rockwell Automation Publication PROCES-SG001D-EN-P - December 2011
What's New?
PlantPAx system release 2.0 improves on existing capabilities to further strengthen our
ability for plant-wide optimization. These latest generation features are described in
the table.
PlantPAx Process Automation System
Description
System high availability
High availability is a critical attribute of the PlantPAx system, and weve added
significant flexibility and scalability without unnecessary investment. The additional
capabilities include the following:
Device Level Ring network topologies, which provide a highly available EtherNet/IP
network without added cost for additional switches and infrastructure.
New redundant I/O modules with redundant controller support for remote I/O on an
EtherNet/IP network.
Single-fault tolerance for native and third-party controllers by using alarm and
events service.
Enhanced diagnostic and error checking on the supervisory layer.
Ability to import large changes into a running controller without disrupting the
non-effected logic.
Ability to edit a sequential function chart online without resetting the chart to its
initial step.
Device integration and asset management
The PlantPAx system has expanded its offerings for connectivity options for
communication protocols, including HART, FOUNDATION Fieldbus, and PROFIBUS PA. These
are examples:
HART solution includes higher density (16-channel) and lower density (2-channel)
modules.
PROFIBUS PA now also supports redundant linking devices.
Fieldbus has new configuration software and a DTM that allows devices supporting
only the EDDL environment to be configured and maintained via the PlantPAx asset
management suite.
Asset management tools also are integrated for intelligent motor control centers,
variable frequency drives, condition monitoring, and power control components.
Design productivity
Careful evaluation of the typical DCS configuration workflows has allowed us to address
steps that can be simplified or accelerated. These include the following:
Initial sizing, architecture design, and documentation to make sure overall system
performance meets or exceeds market expectations.
Expanded PlantPAx library provides more reusable engineering, template objects,
and diagnostics.
Engineering and deployment tools that minimize human error prior to checkout and
testing.
Batch and sequencing control
A wider offering to meet diverse batch requirements includes batch and sequencing
control for small, medium, to large plants. For simpler requirements, our new Logix Batch
and Sequence Manager offers simple configuration and execution and easily integrates
into a higher-level batch strategy for future growth.
For more complex levels, the batch server software adds key capabilities, such as
intelligent recipes, improved runtime user control, expanded data collection and
reporting, and enhanced material management.
Operations productivity
A data management and analysis system to complement any plant size. FactoryTalk
Historian collects and records data locally in the controller chassis, at the site level, or
even larger solutions. Collected data is analyzed and reported to the appropriate user
role, such as maintenance or control operators. The data also is reviewed for optimization
to help deliver reliable production and economic gains.
OEM-sized architecture
The CompactLogix controller platform offers a PlantPAx solution for skid equipment or
turn-key systems in traditional process applications. This initiative introduces a set of
architectures and efficiency tools to not only help equipment manufacturers deliver their
scope quicker, but also offers the end-user simpler integration to, and more consistency
with, their PlantPAx process automation system.
Additional
Resources
These documents contain additional information concerning related products from

Rockwell Automation.
Table 1 - Additional Documentation
Resource
Description
1756 ControlLogix Controllers Technical Data,

publication 1756-TD001
Contains specifications for ControlLogix controllers.
PlantPAx Process Automation System Reference

Manual, publication PROCES-RM001
Provides recommendations for implementing a PlantPAx Process Automation system.
EtherNet Design Considerations Reference

Manual, publication ENET-RM002
Explains the infrastructure components that allow this open network to communicate seamlessly
throughout a plant, from shop floor to top floor.
Converged Plantwide EtherNet (CPwE) Design

and Implementation Guide,
publication ENET-TD001
Provides collaborative design guidelines based on the Cisco Ethernet-to-the-Factory solution and the
Rockwell Automation Integrated Architecture solution.
Ethernet Design Considerations Reference

Manual, publication ENET-RM002
Explains the infrastructure components that allow this open network to communicate seamlessly
throughout a plant, from shop floor to top floor.
ControlNet Media System Components List,

publication AG-PA002
Describes the ControlNet network media components.
Table of Contents
Chapter 1
Process System Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Architecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EtherNet/IP Control Architecture Example. . . . . . . . . . . . . . . . . . . . . . . . 11
ControlNet Control Architecture Example . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Architecture Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
PlantPAx System Release 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Core Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Core Servers and Workstations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Automation System Server (PASS) . . . . . . . . . . . . . . . . . . . . .
HMI Application Server (AppServ-HMI) . . . . . . . . . . . . . . . . . . . . . .
Engineering Workstation (EWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Workstation (OWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skid-based Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engineering Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
16
17
18
18
19
20
20
21
21
22
23
24
25
Chapter 3
Field Device Integration and
Asset Management
EtherNet/IP Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DeviceNet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HART Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOUNDATION Fieldbus Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROFIBUS PA Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Asset Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Asset Management Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
29
30
31
32
33
34
34
34
Chapter 4
Batch Management and Control Basic Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Basic Coded (custom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comprehensive Batch and Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-chassis Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batch High Availability Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
38
38
39
40
41
5
Table of Contents
Chapter 5
Process Information
Data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Decision Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Information Management Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 6
Advanced Process Control
Advanced Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuzzy Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Predictive Control and Real-time Optimization . . . . . . . . . . . . . .
48
49
49
49
Chapter 7
High Availability Systems
High Availability Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

High Availability Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 8
Critical Process Control and
Safety Systems
Process Control Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ControlLogix SIL 1 and SIL 2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Tolerant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fail Safe Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIL Rated Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICS Triplex SIL 2 and SIL 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56
57
58
58
59
59
Chapter 9
PlantPAx Infrastructure
Domain Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Ethernet Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chapter 10
Migration Tools
Migration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter
The PlantPAx system represents the Rockwell Automation culmination of

significant investment in automation technology as it applies to the process
industry. The PlantPAx system unifies core Integrated Architecture process
automation capabilities and technologies with those of market leading partners
under a common systems and solutions umbrella to provide a scalable, open, and
cost-effective process solution.
WAN / Enterprise
Level 5
Enterprise Business
Planning
Patch
Management
Server
Production Workstation
(PWS)
Core System
Field Device Integration / Asset
Management
Batch Management & Control
Process Information
Critical Process Control
& Process Safety
Remote Access
Terminal Server
DMZ
Production
Clients
Application Server
Asset Centre
Application Server
Historian
Production
Printers
Level 3/4
Site Manufacturing
Operations
100 MB EtherNet/IP
Site / Plant Network
Level 2
Supervisory
Control
Process
Automation
System Server
(PASS)
Engineering Workstation
(EWS)
Domain
System
Printers
Application
Application
Server Batch Server Material
Management Management
Operator Workstation
(OWS)
Optional Safety System

Development Workstation
(IsaGraph)
Controller
100 MB EtherNet/IP
Site / Plant Network
Redundant
Controller Pair
Level 1
Process Control
Continuous/
Batch
Local Operator
Workstation
Maintenance
Workstation
MWS
Remote I/O
Controller and
Local I/O
TMR SIL 3 Safety

Controller and I/O
Controller and
Field Network
Bridges
Ethernet I/O Remote I/O
Down Link
Remote I/O Racks
To non-safety
related systems
DeviceNet
SIL 2 Controller
with Fault
Tolerant I/O
Motor Control
Center (MCC)
SIL 2 Safety Controller

Fault Tolerant IO
1400
Termination
Board
Profibus PA
Level 0
Field Devices/
Process
Foundation
Fieldbus HI
Foundation
Fieldbus HI
Foundation
Fieldbus HI
Classic I/O / HART
REDUNDANT
COAX BARRIER
Foundation
Fieldbus HI
In
Channel A
In
Channel B
COMM
CNet Barrier
XM
Condition
Monitoring
Classic I/O / HART
InteliCENTER
(Smart Motor
Control Center)
STATUS
Intrinsically Safe Area

Class 1 Div 1
Field Device Networks

Process Control
HART
Foundation Fieldbus
Profibus PA
Industrial Control
DeviceNet
EtherNet/IP
ASI
Intrinsically Safe Area

Class 1 Div 1
31953-MC
Chapter 1
The PlantPAx system focuses on these main areas.

Table 1 - PlantPAx System Focus Areas
Focus Area
Description
Core system
The core system includes the Integrated Architecture components common to all PlantPAx systems.The
PlantPAx core system consists of the following:
Engineering development environment (development tools)
System-wide visualization (HMI components)
Multi-disciplined process control (control hardware)
Field device integration and

asset management
In addition to supporting an extensive range of I/O products, the PlantPAx system supports integration with
these components:
Field devices, such as HART, FOUNDATION Fieldbus, and PROFIBUS PA, for process instrumentation.
DeviceNet, ControlNet, and EtherNet/IP industrial control devices.
These interfaces provide in-depth integration when used with our device integration tools developed through
our partnership with Endress+Hauser for process instrumentation and drives and motor controls from Rockwell
Automation. Asset management capabilities include code management, vibration monitoring, and device
management.
Batch management and control
The PlantPAx system enables flexible production, equipment-independent recipe management,

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

systems
The PlantPAx system supports scalable solutions that meet specific requirements for availability and safety.
ControlLogix controllers support SIL 1 and SIL 2 requirements.
GuardLogix controllers support SIL 3 requirements.
ICS Triplex Trusted controllers support triple modular redundancy and the scalable AADvance controllers
support SIL 1, 2, and 3 capabilities in simplex, duplex, or triplex configurations. All of the ICS Triplex solutions
are CIP-enabled and part of the Rockwell Automation Integrated Architecture.
Plantwide optimization
The PlantPAx system integrates with Pavilion8 software for predictive control, environmental performance
management, and production performance management.
Infrastructure
Infrastructure components are standard network products (such as Ethernet media and switches) that are based
on open industry standards and provide EtherNet/IP connectivity between Integrated Architecture components,
as well as connectivity to higher level business systems.
Process System Elements
Chapter 1
A PlantPAx system is built on these system elements (combinations of hardware

and software products).
Table 2 - System Elements

System Element
Description
Process automation system server (PASS)
The PASS is a required system element that provides central name resolution and look up services.
The PASS hosts a FactoryTalk View HMI server and an RSLinx Enterprise data server. The PASS
also contains software components for alarms and events.
Operator workstation (OWS)
The OWS provides an interactive graphical interface to monitor and control the process.
Engineering workstation (EWS)
The EWS provides a single development platform for creating and maintaining control strategies and
for configuring system elements. The EWS is also a central storage location for configuration
management.
AppServ-Batch
The batch application server can be an in-chassis or separate computer that runs FactoryTalk Batch
software to provide batch management, information management, process management, and
unit supervision.
AppServ-Information Management
The information management server is the central data point for process information. The
information management server supports both data management and decision support and support
data analysis from the server.
AppServ-Asset Management
The asset management server provides a centralized location to manage end field devices.
AppServ-HMI
HMI application servers provide additional system capacity, as needed.

The number of servers depends on the operational areas of the plant, as well as the number of
these components:
Controllers
Alarms, displays, data logs, and historian tags
Operator workstations
Controller
The ControlLogix controller supports continuous process applications, including Advanced Process
Control functions, with its deterministic, time-based execution mode. The controller supports
continuous, batch, discrete, and motion applications.
Physical location and controller loading affects the number of controllers needed in a
PlantPAx system.
Each controller supports a specified number of field device interfaces.
Each controller has the capacity for a specific number of control strategies, which can be
estimated based on the type of I/O connected to a controller.
Independent workstation (IndWS)
In an independent class architecture, the independent workstation (IndWS) combines the rolls of the
PASS, OWS, and EWS all in one computer.
Chapter 1
Architecture Classes
Rockwell Automation leverages Integrated Architecture technologies and

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

Single Server/ Multiple Clients
Single Server/ Single Client
Table 3 - Architecture Classes

Architecture
Description
System Elements
Independent
An independent class architecture uses a single computer to perform

PASS, EWS, and OWS functions.
One independent workstation
Centralized
The centralized system is a multi-client configuration that supports

the concept of automating a single production or process area. The
system elements can provide main control room operation and enable
you to mount operator workstations locally throughout the production
facility. The centralized system expands the independent system by
adding workstations and controllers.
One dedicated PASS

One dedicated EWS for the development and
maintenance of the full system, including system
security
As many as eight OWS for the interactive
graphical interface
Application servers for batch management, data
acquisition (historian), or change management
(asset management)
Distributed
The distributed system is a multi-server, multi-client configuration

that supports automating a process with semi-independent areas. The
distributed class architecture expands on the centralized class by
adding application servers to interconnect multiple process areas into
a system.
A distributed system can have up to four control areas.
One dedicated PASS

Up to three additional AppServ-HMI to support
additional processing areas and clients
As many as five EWS
As many as eight OWS per PASS or AppServ-HMI
Additional application servers for batch
management, process information, or asset
management if applicable
10
EtherNet/IP Control
Architecture Example
EWS
Chapter 1
This diagram shows an example of an EtherNet/IP supervisory and control

architecture.
Domain
Controller
PASS
Application Servers
Multiple OWS
ETHERNET
Logix5562
POWER
RUN
BAT
RUN
ETHERNET
I/O
REM
ANALOG INPUT
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
OK
FLT
FLT
PROG
RXD
TXD
OK
RXD
TXD
8 9 10 1112131415
RUN
DIAGNOSTIC
RUN
ETHERNET
I/O
FORCE
BAT
DIAGNOSTIC
ETHERNET
Logix5562
POWER
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
OK
AC INTPUT
ST 0 1 2 3 4 5 6 7
RS232
REM
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
ANALOG INPUT
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
OK
FLT
FLT
PROG
RXD
TXD
OK
RXD
TXD
OK
DIAGNOSTIC
OK
REM
PROG
RXD
OK
RXD
TXD
OK
ANALOG INPUT
ANALOG INPUT
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
8 9 10 1112131415
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
DIAGNOSTIC
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
DIAGNOSTIC
TXD
AC INTPUT
ST 0 1 2 3 4 5 6 7
RS232
8 9 10 1112131415
ST 0 1 2 3 4 5 6 7
RS232
BAT
RUN
RUN
FORCE
ETHERNET
I/O
FORCE
ETHERNET
Logix5562
POWER
Device-level Ring Topology

Star Topology
ETHERNET
Logix5562
POWER
RUN
FORCE
BAT
RUN
ST 0 1 2 3 4 5 6 7
RS232
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
OK
REM
ANALOG INPUT
I/O
PROG
RXD
TXD
OK
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
Module
Status
Module
Status
NODE:
NODE:
Relay
Output
120 VAC
Input
1
2
3
1734
OW4
1
2
Network
Status
Network
Status
Network
Status
NODE:
NODE:
6 2
3
1734
IM4
7 3
1734
IB8
NODE:
120V
220 VAC
Output
5 1
24VDC
Source
Output
4 0
1734
IA4
24VDC
Sink
Input
220 VAC
Input
5
6
1734
OB8E
1
2
220VAC
Input
5
6
1
2
3
1734
OA4
1734
IM4
ControlNet Control
Architecture Example
EWS
NODE:
DeviceBus
Status
1734-ADNX
NODE:
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
Network
Status
Network
Status
DeviceNet
Status
DIAGNOSTIC
Module
Status
Module
Status
Module
Status
This diagram shows an example of an EtherNet/IP supervisory and ControlNet

control architecture.
PASS
Domain
Controller
Application Servers
Multiple OWS
EtherNet/IP
Redundant Controllers
ControlNet
11
Chapter 1
Recommended
Architecture Sizes
Use these system elements in your process architecture.
Table 4 - Architecture System Elements

System Element
Independent Class
Centralized Class
Distributed Class
PASS
Single computer serves as PASS, EWS,

and OWS in an independent
workstation
One PASS required and includes:

FactoryTalk Directory server
HMI server
Data server
Alarms and Events Server
One PASS required and includes:

FactoryTalk Directory server
HMI server
Data server
Alarms and Events Server
(optional)(1)
EWS
Included in independent workstation
1 EWS required
Can have as many as 5 EWS
1 EWS required
Can have as many as 5 EWS
OWS
Included in independent workstation
8 remote clients
8 remote clients for PASS

8 additional remote clients per
AppServ-HMI
Domain controller
Required if there are 10 or more

Ethernet nodes (IP addresses)
Required
Required
Process controller(2)
1...5 ControlLogix controllers
1...6 ControlLogix controllers
1...6 ControlLogix controllers per PASS

1...6 ControlLogix controllers per
AppServ-HMI
Application servers
None
One AppServ-Batch
One AppServ-Information Management
One AppServ-Batch for each set of six

controllers
One AppServ-Information Management
Three AppServ-HMI
(1) The PlantPAx system is limited to two FactoryTalk Alarms and Events servers per system, with each supporting up to 10,000 alarms.
(2) Controller count based on fully-loaded L63 controllers. Actual controller count allowed may vary based on controller selection and loading. See the next chapter for
controller details.
Rockwell Automation offers the Integrated Architecture Builder (IAB) tool that
you can use to configure an automation system. It helps you select hardware and
generate bills of material for applications that include controllers, I/O, networks,
drives, cabling and wiring, motion control, and other devices. IAB also includes a
Process System Estimator (PSE) to size your process control hardware.
See http://www.rockwellautomation.com/en/e-tools/configuration.html.
12
Chapter
The PlantPAx core system consists of the components required to engineer and
maintain a process system. This includes system servers, workstations, and
controllers.
EWS
Domain
Controller
PASS
Application Servers
Multiple OWS
ETHERNET
Logix5562
POWER
RUN
RS232
BAT
RUN
RUN
FORCE
BAT
RUN
ETHERNET
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
ST 0 1 2 3 4 5 6 7
RS232
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
FLT
OK
REM
ANALOG INPUT
I/O
PROG
RXD
TXD
OK
RXD
TXD
8 9 10 1112131415
RUN
FORCE
BAT
DIAGNOSTIC
ETHERNET
Logix5562
POWER
8 9 10 1112131415
DIAGNOSTIC
OK
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
DIAGNOSTIC
RUN
ETHERNET
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
ST 0 1 2 3 4 5 6 7
RS232
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
FLT
OK
REM
ANALOG INPUT
I/O
PROG
RXD
TXD
OK
RXD
TXD
OK
8 9 10 1112131415
DIAGNOSTIC
OK
REM
PROG
RXD
ETHERNET
Logix5562
POWER
RUN
I/O
FORCE
PROG
ANALOG INPUT
FLT
OK
REM
OK
RXD
TXD
OK
ANALOG INPUT
ANALOG INPUT
ST 0 1 2 3 4 5 6 7
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
FLT
FLT
8 9 10 1112131415
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
DIAGNOSTIC
8 9 10 1112131415
DIAGNOSTIC
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
RS232
BAT
RUN
TXD
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
ETHERNET
I/O
FORCE
ETHERNET
Logix5562
POWER
RXD
TXD
OK
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
8 9 10 1112131415
DIAGNOSTIC
Module
Status
Module
Status
NODE:
NODE:
NODE:
Network
Status
Network
Status
Network
Status
NODE:
NODE:
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
NODE:
NODE:
DeviceBus
Status
Relay
Output
1734-ADNX
120 VAC
Input
1
2
3
1734
OW4
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
DeviceNet
Status
DIAGNOSTIC
1
2
6 2
3
1734
IM4
7 3
1734
IB8
120V
220 VAC
Output
5 1
24VDC
Source
Output
4 0
1734
IA4
24VDC
Sink
Input
220 VAC
Input
5
6
1734
OB8E
1
2
220VAC
Input
5
6
1
2
3
1734
OA4
1734
IM4
Topic
Page
Core Control Hardware
14
I/O Components
16
Redundant Networks
18
Core Servers and Workstations
20
Redundant Servers
23
Skid-based Equipment
24
Engineering Tools
25
13
Chapter 2
PlantPAx System
Release 2.0
The PlantPAx system release 2.0 consists of the following software:

RSLogix 5000 software, version 19.x
FactoryTalk View software, version 6.0
FactoryTalk Batch software, version 11
FactoryTalk AssetCentre software, version 4.0
FactoryTalk VantagePoint software, version 3.1.5
FactoryTalk Historian software, version 2.2
Core Control Hardware
The core control components are the ControlLogix family of products. The
ControlLogix controller functions as the process controller and provides process,
sequential, discrete, and drive control. Separate modules provide connectivity to
system networks, field devices, and third-party products.
Table 5 - Simplex Controller Hardware

Hardware
Product
Process controller(1) (2)
ControlLogix 1756-L61, 1756-L62, or 1756-L63 controller

ControlLogix 1756-L72, 1756-L73, 1756-L74, or 1756-L75 controller
Ethernet interface
1756-EN2TR, 1756-EN3TR, 1783-ETAP (supports device-level ring topology)

1756-EN2T, 1756-ENBT, 1756-EWEB, 1756-EN2F, 1783-ETAP1F, 1783-ETAP2F. The fiber 1783ETAPs support device-level ring topology.
ControlNet interface
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
(1) If environmental conditions warrant, you can use an extreme temperature controller, for example, the 1756-L74XT.
(2) For a PlantPAx system, we recommend that you use only the controller platforms characterized in this table. If 1756-L64 or 1756-L65 controllers are used, be aware that
the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756-L63 controller (typically 1015%).
Table 6 - Simplex ControlLogix Controller Sizing

Attribute(1)
1756-L61
1756-L62
1756-L63
1756-L72
1756-L73
1756-L74
1756-L75
User memory
2 MB
4 MB
8 MB
4 MB
8 MB
16 MB
32 MB
Total I/O recommended, max
375
750
1500
750
1500
2250
2250
Total tags, max
15,625
31,250
62,500
31,250
62,500
112,500
112,500
Recommended control strategies, max(2)
60
125
250
125
250
450
450
Total control strategies @ 250 ms, max
60
125
125
125
250
250
250
60
125
250
125
250
450
450
Tags/sec delivered to data server, max(3)
10,000
10,000
10,000
20,000
20,000
20,000
20,000
(1) These values are maximum limits. You may not be able to achieve all of these in a single controller.
(2) Representative control strategy (PID loop) includes 1 analog input, 1 analog output, 1 PIDE instruction, 8 logic/math instructions, and 22 alarms with PlantPAx
process objects.
(3) Assumes RSLinx Enterprise software, version 5.30, at 10 K/s per instance.
14
Chapter 2
ControlLogix controllers support redundancy on ControlNet and EtherNet/IP

networks. In a redundant controller system on PlantPAx, you need
these components:
Two 1756 chassis each set up the same with the following:
Number of slots
Modules in the same slots
Redundancy firmware revisions in each module
Two additional ControlNet or Ethernet nodes outside the redundant
chassis pair
One 1756-RM module per chassis
Table 7 - Redundant Controller Hardware
Hardware
Product
Process controller(1)
ControlLogix 1756-L63 controller, firmware revision 19.x

ControlLogix 1756-L73, 1756-L74, or 1756-L75 controller, firmware revision 19.x
Redundancy module
1756-RM
Redundant Ethernet network
A redundant Ethernet network is based on architecture topology and requires multiple Ethernet
interfaces.
1756-EN2T, 1756-EN2TR
Redundant ControlNet network
A redundant ControlNet network requires a ControlNet interface that support redundant media
1756-CN2R
(1) For a PlantPAx system, we recommend that you use only the controller platforms characterized in this table. If 1756-L64 or 1756-L65 controllers are used, be aware that
the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756-L63 controller (typically 1015%).
Table 8 - Redundant ControlLogix Controller Sizing

Attribute(1)
1756-L63
1756-L73
1756-L74
1756-L75
User memory
8 MB
8 MB
16 MB
32 MB
750
750
1500
2250
Total tags, max
31,250
31,250
62,500
125,000
125
125
250
450
60
120
120
120
120
125
220
220
10,000
20,000
20,000
20,000
process objects.
15
Chapter 2
I/O Components
I/O components consist of standard I/O modules as well as intelligent and

specialty modules. The number of I/O components depends on the number of
controllers.
Table 9 - I/O Product Family and Communication Interface

Category
Product
Connectivity
In-cabinet I/O modules
1734 POINT I/O
1734-AENT EtherNet/IP adapter

1734-ACNR ControlNet adapter (redundant)
1734-ADN, 1734-ADNX, 1734-PDN DeviceNet adapter
1790 CompactBlock LDX I/O
Built-in DeviceNet connectivity
1791D CompactBlock I/O
1794 FLEX I/O

1794-ACN15, 1794-ACNR15, 1794-ACN15K, 1794-ACNR15K
ControlNet adapter
1794-ADN DeviceNet adapter
1797 FLEX Ex intrinsically safe I/O
1797-ACNR15 ControlNet adapter

1794 adapter with 1797-BIC isolator and 1797-CEC connector
1732 ArmorBlock I/O
Built-in EtherNet/IP or DeviceNet connectivity
1738 ArmorPOINT I/O

1738-ACNR ControlNet adapter
1738-ADN12, 1738-ADN18, 1738-ADN18P, 1738-ADNX DeviceNet
adapter
1799 Embedded I/O
Chassis-based I/O modules
1756 ControlLogix I/O
1756-EN2T, 1756-EN2TR, 1756-EN2F, 1756-ENBT EtherNet/IP

module
1756-CN2, 1756-CN2R, 1756-CNB, 1756-CNBR ControlNet module
1756-DNB module
Variable frequency drives
PowerFlex drives
Some drives offer built-in EtherNet/IP connectivity; others require

separate adapter:
20-COMM-E EtherNet/IP adapter
20-COMM-C, 20-COMM-Q ControlNet adapter
20-COMM-D DeviceNet adapter
Soft motor starters
150 SMC smart motor controller
Overload relays
193 E1 overload relays

592 E3 overload relays
Built-in EtherNet/IP or DeviceNet connectivity
Motor control centers(1)
CENTERLINE 2100
CENTERLINE 2500
Built-in EtherNet/IP connectivity or via 1788-EN2DN linking device

ControlNet connectivity via 1788-CN2DN linking device
Condition monitoring
1440 XM intelligent I/O modules

ControlNet connectivity via 1440-ACNR ControlNet adapter with
1440-DYN02-01RJ module only
On-machine I/O modules
(1) Networked motor control center devices can be used in place of standard I/O modules (digital and analog outputs).
16
Chapter 2
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.
Device-level Ring
EtherNet/IP Network
Redundant I/O Modules
The 1715 I/O system supports as many as 24 I/O modules per set of adapters.
Table 10 - 1715 I/O Modules
Cat. No.
Description
1715-AENTR
EtherNet/IP adapter
1757-IB16D
16 point, 24V DC diagnostic input module
1715-OB8DE
8 point, 24V DC diagnostic output module, electronically fused
1715-IF16
16 channel, 420 mA, current analog input module
1715-OF8I
8 channel, 420 mA, current analog output module, isolated
17
Chapter 2
Redundant Networks
Consider your topology when weighing redundancy options for EtherNet/IP

and ControlNet networks.
EtherNet/IP Network
Ethernet networks have active infrastructures that rely on switches for managing
traffic. You can design a network with individual switch devices and devices that
have embedded switch technology.
Table 11 - Redundant EtherNet/IP Topologies
Topology
Description
Redundant Star
Recommended for supervisory networks.
A redundant star topology is essentially where every Layer 2 access switch has
dual connections to a Layer 3 distribution switch. Devices are connected to the
Layer 2 switches.
Advantages
Resiliency from multiple connection
failures
Faster convergence to connection
loss
Consistent number of hops provide
predictable and consistent
performance
Fewer bottlenecks
Device-level ring (DLR)

Recommended for control and I/O networks.
A DLR network is a single-fault tolerant ring network intended for the

interconnection of automation devices. This topology has switches embedded into
the end devices themselves; no additional switches are required.
The DLR topology does require additional effort to set up and use as compared to
a linear network.
Advantages
Ability to survive a single point of
failure or a device being powered
down on the ring
Simplified cabling
Ability to cover long distances
with 100 m allowed between each
copper segment
Very fast network convergence
18
Disadvantages
Additional wiring and ports required
Additional configuration complexity
Disadvantages
Supervisor-node configuration
required
Variable number of hops can make
performance difficult to predict
Chapter 2
Table 11 - Redundant EtherNet/IP Topologies

Topology
Description
(1)
Switch ring
A switch ring network is a single-fault tolerant ring network that connects Layer 2
switches to a Layer 3 distribution switch.
Advantages
Ability to survive a single point of
failure or a device being powered
down on the ring
Simplified cabling
Ability to cover long distances with
100 m allowed between each copper
segment
Disadvantages
Longer convergence times
Variable number of hops can make
performance difficult to predict
(1) Not characterized with PlantPAx system testing, but assumed a valid configuration.
Additional Ethernet features that support high availability include these

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

A ControlNet network supports the option of redundant media.
ControlLogix
1756-C2NR
ControlNet Node
Redundant Media
ControlNet Node
For information on ControlNet media, see ControlNet Media System

Components List, AG-PA002.
19
Chapter 2
Core Servers and

Workstations
The PlantPAx system uses these core servers and workstations:

Process automation system server (PASS)
HMI application server (AppServ-HMI)
Engineering workstation (EWS)
Process Automation System Server (PASS)

The process automation system server (PASS) is the process system server. The
PASS can also provide HMI, data, and OPC server functions. In an independent
class architecture, the PASS also serves as the engineering workstation (EWS) and
operator workstation (OWS).
Table 12 - PASS Requirements
Attribute
Product
Computer hardware
Operating system
Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service) with
Service Pack 2, 32-bit
Visualization
FactoryTalk View SE server software

FactoryTalk View SE client software
FactoryTalk View Studio software(1)
Infrastructure
Additional
Antivirus software
OPC interface software
Pentium Core Duo processor or better

1.6 GHz CPU
4 GB memory
Dual hard drives (one for application code; one for logging)
Dedicated Ethernet card that supports redundant media
UPS power backup
FactoryTalk Services Platform server software

FactoryTalk Directory software
FactoryTalk View Administration Console software
RSLinx Enterprise software (includes FactoryTalk Alarms and Events server)
RSLinx Classic software (not activated)
FactoryTalk Activation server software
FactoryTalk Historian interface node
(1) Required only for initial setup. Take advantage of concurrent licensing with an EWS.
Predefined PASS Products

These servers are available as prepackaged hardware and software products based
on the PlantPAx characterized system elements.
20
Cat. No.
Description
7477-IS2VS100
Process automation system server (PASS) with 100 screens
7477-IS2VS250
Process automation system server (PASS) with 250 screens
Chapter 2
HMI Application Server (AppServ-HMI)

Add additional HMI application servers as needed based on operational areas in
the plant or based on the number of these components:
Controllers
Alarms, displays, data logs, and historian tags
Operator interfaces
Table 13 - AppServ-HMI Requirements
Attribute
Product
Computer hardware
Operating system
Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service) with
Service Pack 2
Visualization
FactoryTalk View SE server software

FactoryTalk View Studio software
Infrastructure
Additional
Microsoft Office 200x software

Antivirus software
OPC interface software

1.6 GHz CPU
4 GB memory
UPS power backup

RSLinx Enterprise software (includes FactoryTalk Alarms and Events server)
RSLinx Classic software (not activated)
FactoryTalk Activation client software
FactoryTalk Historian interface node
Engineering Workstation (EWS)

The engineering workstation (EWS) supports system configuration, application
development, and maintenance functions. This is the central location for
monitoring and maintaining the systems operation.
Table 14 - EWS Requirements
Attribute
Product
Computer hardware
Operating system
Windows XP Professional operating system

Windows 2008 Server operating system (if more than 10 nodes and activation server); 32-bit
Control development
RSLogix 5000 Professional Edition software (includes Advanced Process Control function blocks)
RSLogix Architect software
RSLogix Emulate 5000 software
Pentium 4 processor or better

3.0 GHz CPU
3 GB memory
ATI video card
Dedicated Ethernet card
UPS power backup
21
Chapter 2
Table 14 - EWS Requirements

Attribute
Product
Visualization development

FactoryTalk View Studio software
Batch management, optional(1)
Asset management, optional(1)
FactoryTalk AssetCentre client software

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

FactoryTalk Historian Datalink software
FactoryTalk Historian Batch View software
FactoryTalk Historian SQC software
FactoryTalk VantagePoint development tools
IntelliCENTER software for Motor Control Centers
Infrastructure
FactoryTalk Services Platform software

RSLinx Enterprise software
RSLinx Classic software(2)
FactoryTalk Security server software(1)
Optional configuration
Fuzzy Designer software

IntelliCENTER software for motor control centers
RSFieldbus software for FOUNDATION Fieldbus devices
HIPROM HSNetworxPA software for PROFIBUS PA devices
Endress+Hauser Fieldcare software
RSNetWorx for ControlNet software
Additional
Microsoft Office software

Antivirus software
FactoryTalk Batch Equipment Editor software

FactoryTalk Batch Recipe Editor software
FactoryTalk Batch View client software
FactoryTalk Batch MaterialManager software
(1) The EWS has the client and configuration tools. You need the associated application server for runtime services.
(2) Included with RSLogix 5000 Professional Edition software, version 19.x.
Operator Workstation (OWS)

The operator workstation (OWS) provides the graphical view and interface into
the process. The workstation is a client of either a PASS or application HMI
server. The OWS supports operator interaction and is not meant to support
development or maintenance activities.
Table 15 - OWS Requirements
Attribute
Product
Computer hardware
Operating system
Windows XP Professional operating system with Service Pack 3
Visualization
Batch management, optional(1)
FactoryTalk Batch client software

FactoryTalk Batch eProcedure software
22

1.6 GHz CPU
4 GB memory
UPS power backup
Chapter 2
Table 15 - OWS Requirements

Attribute
Product
(1)
Process information, optional
FactoryTalk Historian Active View (ProcessBook) client software
Infrastructure
FactoryTalk Services Platform software

Additional

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

This OWS is available as prepackaged hardware and software products based on
the PlantPAx characterized system elements.
Redundant Servers
Cat. No.
Description
7477-IC2VC
Based on risk analysis of the probability and impact of a component failure, you
may choose to make that component redundant in your architecture. That may
include servers, controllers, network, or infrastructure.
The PASS and AppServ-HMI servers can be configured as redundant for the
following software components:
HMI server
Alarm server
Data server
Primary Server
Secondary Server
For more information about configuration details, see the PlantPAx Process
Automation System Reference Manual, publication PROCES-RM001.
23
Chapter 2
Skid-based Equipment
The PlantPAx process automation system is a complete, scalable system, from

single controller to a fully distributed set of equipment. You can easily integrate
skid-based equipment into the overall system.
The CompactLogix controller platform offers a solution for skid-based
equipment or turn-key system:
The application requires the control of multiple loops for temperature,
pressure, flow, or level.
The application runs as a sub-system with sequencing and automation.
The application is controlled as part of the overall process, accepting
reference inputs and delivering process variables to an overall
programmable controller.
Table 16 - Skid-based Controller Sizing

Attribute(1)
CompactLogix 1769-L23E
CompactLogix 1769-L35E
User memory
0.5 MB
1.5 MB
80
250
Total tags, max
4000
12,800
10
30
10
30
10
30
3000
3000
process objects.
24
Engineering Tools
Chapter 2
The PlantPAx solution includes additional tools that can be used to develop your
process application, in conjunction with the standard Integrated Architecture
tools such as RSLogix 5000 software.
Table 17 - Engineering Tools

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

Automation Knowledgebase at http://www.rockwellautomation.com/
knowledgebase/. See Knowledgebase Answer ID 62366 for the PlantPAx table of
contents.
Some downloads may require a TechConnectSM contract.
25
Chapter 2
Notes:
26
Chapter
Field Device Integration and

Asset Management
Field device components connect process instrumentation and electrical
(power) products. Field device components can communicate through the
EtherNet/IP, DeviceNet, ControlNet, HART, FOUNDATION Fieldbus, and
PROFIBUS PA networks.
EtherNet/IP
FOUNDATION
Fieldbus
EtherNet/IP
ControlNet
HART
FOUNDATION
Fieldbus
PROFIBUS PA
Topic
Page
EtherNet/IP Devices
28
ControlNet Devices
29
DeviceNet Devices
30
HART Devices
31
FOUNDATION Fieldbus Devices
32
PROFIBUS PA Devices
33
Asset Management
34
27
Chapter 3
Field Device Integration and Asset Management
EtherNet/IP Devices
The EtherNet/IP network protocol is an open, industrial-networking standard

that supports both real-time I/O messaging and message exchange. The
EtherNet/IP network uses off-the-shelf Ethernet products and physical media.
EtherNet/IP Network
ETHERNET
Logix5562
POWER
RUN
RS232
BAT
RUN
ETHERNET
I/O
FORCE
FOUNDATION
Fieldbus Network
OK
REM
PROG
RXD
TXD
OK
RXD
TXD
OK
ANALOG INPUT
ANALOG INPUT
ST
0 1 2 3 4 5 6 7
ST
0 1 2 3 4 5 6 7
FLT
0 1 2 3 4 5 6 7 O
8 9 10 1112131415 K
FLT
ST
ST
0 1 2 3 4 5 6 7 O
8 9 10 1112131415 K
FLT
8 9 10 1112131415
FLT
8 9 10 1112131415
DIAGNOSTIC
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
DIAGNOSTIC
HART
Devices
ETHERNET
Logix5562
POWER
RUN
I/O
FORCE
RS232
BAT
RUN
OK
REM
PROG
RXD
TXD
OK
ANALOG INPUT
ST
0 1 2 3 4 5 6 7
FLT
ST
0 1 2 3 4 5 6 7 O
8 9 10 1112131415 K
FLT
8 9 10 1112131415
DIAGNOSTIC
AC INTPUT
ST 0 1 2 3 4 5 6 7 O
ST 8 9 10 1112131415 K
Module
Status
Module
Status
NODE:
NODE:
Module
Status
Module
Status
Module
Status
NODE:
NODE:
Network
Status
Network
Status
Network
Status
NODE:
NODE:
Module
Status
Module
Status
Module
Status
Network
Status
Network
Status
Network
Status
Network
Status
DeviceNet
Status
DIAGNOSTIC
NODE:
DeviceBus
Status
Relay
Output
1734-ADNX
120 VAC
Input
1
2
3
1734
OW4
Motor Control
Center
1
2
6 2
3
1734
IM4
7 3
1734
IB8
120V
220 VAC
Output
5 1
24VDC
Source
Output
4 0
1734
IA4
24VDC
Sink
Input
220 VAC
Input
5
6
1734
OB8E
1
2
220VAC
Input
5
6
1
2
3
1734
OA4
1734
IM4
PROFIBUS PA
Network
In a PlantPAx system, the EtherNet/IP network provides the communication

backbone for the supervisory network for the workstations, servers, and the
controllers. The EtherNet/IP network also supports controller downlinks and
connections to remote I/O and field device interfaces. EtherNet/IP is supported
by the Open Device Vendors Association (ODVA).
Table 18 - EtherNet/IP Interface
Category
Product
Description
ControlLogix controller interface
1756-EN2T, 1756-EN2TR,1756-EN2F
1756-ENBT
1756-EWEB
ControlLogix EtherNet/IP scanner.
1757-FFLD2
1757-FFLD4
EtherNet/IP to FOUNDATION Fieldbus linking device. Supports two or

four H1 FOUNDATION Fieldbus networks.
1788HP-EN2PA-R(1)
HIPROM Technologies, EtherNet/IP to PROFIBUS PA linking device.

Supports redundant PA media and DLR capable Ethernet.
(1) Can be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.
Some field devices support a direct connection to EtherNet/IP networks. For

example:
Endress+Hauser, Promass 80 and Promass 83 Coriolis flowmeters for
liquid and gas flows
Endress+Hauser, Promag 53 electromagnetic flowmeter for conductive
liquids
28
Chapter 3
Many I/O and field device products are available via the Encompass third-party
product referencing program. To sort and filter products from best-in-industry
suppliers in your region, see http://www.rockwellautomation.com/encompass.
ControlNet Devices
The ControlNet network is an open, control network for real-time,

high-throughput applications that uses the Common Industrial Protocol (CIP)
to combine the functionality of an I/O network and a peer-to-peer network,
providing high-speed performance for both functions. ControlNet is supported
by the Open Device Vendors Association (ODVA).
EtherNet/IP Network
ControlNet Network
HART
Devices
FOUNDATION
Fieldbus Network
PROFIBUS PA
Network
In a PlantPAx system, the ControlNet network supports controller downlinks

and connections to remote I/O and field device interfaces.
Table 19 - ControlNet Interface
Category
Product
Description
1756-CN2, 1756-CN2R
1756-CNB, 1756-CNBR
ControlLogix ControlNet scanner.
1757-FFLDC2
1757-FFLDC4
ControlNet to FOUNDATION Fieldbus linking device. Supports two or

four H1 networks. Compatible with ControlLogix redundancy and
redundant ControlNet media.
1788HP-CN2PA-R(1)
HIPROM Technologies, ControlNet to PROFIBUS PA linking device.

Supports redundant PA media and redundant ControlNet media.
(1) Can be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.
29
Chapter 3
DeviceNet Devices
The DeviceNet network is an open, device-level network that provides

connections between simple industrial devices (such as sensors and actuators) and
higher-level devices (such as PLC controllers and computers). The DeviceNet
network uses the proven Common Industrial Protocol (CIP) to provide the
control, configuration, and data collection capabilities for industrial devices.
DeviceNet is supported by the Open Device Vendors Association (ODVA).
DeviceNet Network
CENTERLINE
Motor Control Center
PowerFlex
Drives
In a PlantPAx system, the DeviceNet network connects networked control

devices.
Table 20 - DeviceNet Interface
Category
Product
Description
1756-DNB
ControlLogix DeviceNet scanner
30
HART Devices
Chapter 3
HART is an open protocol designed to connect analog devices.
Controller Network
HART Devices
The PlantPAx system interfaces both directly and via remote I/O modules to
provide a single termination point to gather analog process variables and the
additional HART digital data.
Table 21 - HART Interface
Category
Product
Description
Chassis-based I/O modules
1756-IF8H, 1756-OF8H
1756-IF16H
ControlLogix analog I/O modules with the following:

Standard profiles in RSLogix 5000 software
DTMs
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 (IEC-62453, ISA103).
1734-sc-IF4H
Spectrum Controls, analog input module with HART for the

POINT I/O system.
1769-sc-IF4IH, 1769-sc-OF4IH
Spectrum Controls, analog, isolated input and output modules with

HART for Compact I/O.
1794-IE8H, 1794-OE8H
1794-IF8IH, 1794-OF8IH
1797-IE8H, 1797-OE8H
FLEX analog I/O and FLEX Ex analog I/O modules with the following:
Standard profiles in RSLogix 5000 software
DTMs
EtherNet/IP interface
Spectrum Controls, HART I/O with an EtherNet/IP interface.

See the Encompass website for Spectrum product offerings.
Wireless HART adapter
Pepperl+Fuchs, wireless HART adapter.

See the Encompass website for Pepperl+Fuchs product offerings.
Handheld device
Endress+Hauser, handheld configuration and diagnostic device.

See the Encompass website for Endress+Hauser product offerings.
Distributed I/O modules
Multiplexers/gateways
Network configuration
HART device integration tools include the following:

Pre-engineered controller code with Add-On Instructions that provide
two-way exchange of data between faceplates and the ControlLogix
controller
Pre-configured operator faceplates that provide visualization of
instruments connected to the network interface
Integration documentation that describes the implementation, at
http://www.rockwellautomation.com/solutions/process/integrationdocs.
html
For information about using Add-On Instructions and faceplates with HART
data in a FactoryTalk View SE application, see the Rockwell Automation
Knowledgebase Answer ID 54847 at http://rockwellautomation.custhelp.com.
31
Chapter 3
FOUNDATION Fieldbus
Devices
The FOUNDATION Fieldbus network is a protocol designed for robust,

distributed control of process control applications. Devices connected by a
FOUNDATION Fieldbus network can be used for sophisticated,
highly-distributed process control.
EtherNet/IP Network
ControlNet Network
1757-FFLDC2 or
1757-FFLDC4
1757-FFLD4
H1 (1)
H1 (2)
H1 (3)
H1 (4)
PlantPAx systems communicate with FOUNDATION Fieldbus devices through

EtherNet/IP and ControlNet linking devices.
Table 22 - FOUNDATION Fieldbus Interface
Category
Product
Description
EtherNet/IP interface
1757-FFLD2
1757-FFLD4
Bridge from an Ethernet network to either two or four H1 networks.
ControlNet interface
1757-FFLDC2
1757-FFLDC4
Bridge from a ControlNet network to either two or four H1 networks;

compatible with ControlLogix redundancy and redundant ControlNet
media.
FOUNDATION Fieldbus network

components
Power conditioning
Segment protection
Pepperl+Fuchs, FOUNDATION Fieldbus components, such as valve

couplers, surge protectors, terminators, distributors, and power
products.
9308 series RSFieldbus software
Configure FOUNDATION Fieldbus devices.
Configuration software
Terminators
FOUNDATION Fieldbus device integration tools include the following:

two-way exchange of data between faceplates and the ControlLogix
controller
html
32
PROFIBUS PA Devices
Chapter 3
The PROFIBUS PA network is the PROFIBUS solution for process automation.

The PROFIBUS PA network connects automation systems and process control
systems with field devices such as flow, level, pressure, and temperature
transmitters.
EtherNet/IP Linear
EtherNet/IP Device Level Ring
EtherNet/IP
Redundant ControlNet
PROFIBUS PA
Linking Devices
PROFIBUS PA Linking Devices
PROFIBUS PA Devices
PROFIBUS PA Devices
PROFIBUS PA Devices
Table 23 - PROFIBUS PA Interface

Category
Product
Description
PROFIBUS interface
1788HP-EN2PA-R(1)
HIPROM Technologies, EtherNet/IP to PROFIBUS PA linking device.

Supports redundant PA media and DLR capable Ethernet. Linking
device includes power conditioning.
1788HP-CN2PA-R(1)
HIPROM Technologies, ControlNet to PROFIBUS PA linking device.

Supports redundant PA media and redundant ControlNet media.
Linking device includes power conditioning.
Power conditioning
HIPROM Technologies, linking devices have built-in power

conditioning.
Junction boxes
HIPROM Technologies, intelligent junction box PAR-JB (4 junctions)

and PAR-JB6 (6 junctions) support redundancy and do not require
separate power supplies.
Power conditioning
Pepperl+Fuchs, PROFIBUS components, such as valve couplers, surge

protectors, terminators, distributors, and power products.
PROFIBUS network components
PROFIBUS network components
Terminators
Segment protection
(1) Must be ordered directly from HIPROM Technologies; not a Rockwell Automation product catalog number.
PROFIBUS PA device integration tools include the following:

two-way exchange of data between faceplates and ControlLogix controller
html
33
Chapter 3
Asset Management
Asset management is an extension to the PlantPAx system that adds maintenance

and plant operations to the core components. This includes comprehensive
diagnostics, calibration, real-time monitoring, as well as auditing equipment and
network health to improve overall resource availability.
Asset Management Server

The asset management server provides a centralized system management for end
field devices.
Table 24 - Asset Management Server Requirements
Attribute
Product
Computer hardware
Operating system
Windows 2003 Server operating system
Asset management software
Optional software
IntelliCENTER software for motor control centers

3.0 GHz CPU
2 GB memory
UPS power backup
FactoryTalk AssetCentre server software

FactoryTalk AssetCentre assets (5, 25, 100, 500, 1000, or 5000)
FactoryTalk AssetCentre Disaster Recovery Rockwell Automation software
Microsoft SQL Server 2000 software
Calibration Products
These calibration tools are available to manage calibration requirements,
specifications, schedules, calibration results, and reports.
Table 25 - Calibration Products
Product
Description
Process device configuration tool
9515-ASTPRDCFENE FactoryTalk AssetCentre Process Device Configuration software
Calibration management tool
Loop
705, 707, 707Ex, 715
Fluke handheld process-loop calibrators for the calibration and troubleshooting of 4...20 mA process
control loops
Multifunction
725, 741, 743B, 744
Fluke handheld, multifunction calibrators for temperature, pressure, voltage, and mA parameters
Pressure
717, 718, 718Ex, 719
Fluke pressure calibrators measure pressure to 0.05%, DC mA. The 718 and 718Ex have an onboard
pump. Ranges: 30 and 100 PSIG
Temperature
712, 714, 724
Fluke temperature calibrators include the following:

712: RTD source/measure
714: thermocouple (T/C) source/measure
724: source/measure RTD, T/C, measure mA, 24V loop
34
9515-ASTCLMANENE FactoryTalk AssetCentre Calibration Management software

9515-ASTCLWRKENE FactoryTalk AssetCentre Calibration Management remote workstation
9515-ASTCLFLKENE FactoryTalk AssetCentre Calibration Management FLUKE interface
9515-ASTCLDRKENE FactoryTalk AssetCentre Calibration Management Druck interface
9515-ASTCLTMNENE FactoryTalk AssetCentre Calibration Management Trnsmtn interface
Chapter
Batch Management and Control
PlantPAx batch management and control solutions offer flexible production,

equipment-independent recipe management, batch-independent equipment
control, and regulatory compliance. The scalable integrated solutions leverage
industry standards to meet small, basic batch and sequencing needs, as well as
distributed, comprehensive batch and sequencing needs.
System size varies from small to large and system requirements vary from simple
to complex. Not all basic systems are small or have simple requirements, and not
all comprehensive system are large or complex. Small systems can have complex
requirements or vice versa.
Topic
Page
Basic Batch and Sequencing
37
Comprehensive Batch and Sequencing
38
35
Chapter 4
Basic solutions provide capabilities for small or simple systems to use core system
functions, including Logix5000 controllers and FactoryTalk View HMI.
Generally these solutions do not need the functionality provided by server-based
FactoryTalk Batch software solutions.
Comprehensive solutions provide capability for large or complex systems to use
modular software components. This includes FactoryTalk Batch software,
eProcedure software, Material Manager software, integrated visualization, batch
reporting services, and integrated security and audit services.
Each solution can migrate to the next. These four solutions overlap because each
individual solution can solve many of the same core requirements. All solutions
support PhaseManager software and the PlantPAx Process Library.
Table 26 - Select a Batch Solution
Batch Application Function
Basic Coded
Basic Configured
Custom coded solution

(changes to recipe require code change)
Leverage PhaseManager and SFC programming

(based on built-in controller-firmware functionality)
Standard controller/HMI application solution without

the need for a separate server
(no server or additional software required, limited by
controller memory)
Comprehensive
In-Chassis Server
Comprehensive
Application Server
Single unit execution

(product made in single unit)
Recipe management
(configurable and flexible formula, procedure, and
equipment)
Data collection, reporting, and analysis

(requires sever for long term storage and analysis)
Equipment allocation and arbitration

(shared resources and/or shared resources)
Complex recipes
(product recipes with loops, branches, and transitions;
phases with more than four inputs and four outputs)
Multiple unit coordination

(product is made across multiple, coordinated units)
More than 32 recipes
String values or numeration required for parameter

and report values
Number of parameters or report values required

by phase > 4
Require class-based recipes
36
Chapter 4
Table 26 - Select a Batch Solution

Batch Application Function
Basic Coded
Basic Configured
Comprehensive
In-Chassis Server
Comprehensive
Application Server
Large system with complex routing

(more than five units; may use complex routing
algorithms)
Manual and electronic work instructions

(web-based instructions, embedded pictures, video)
Material management
(material container, lot, location, and property
tracking)
Basic Batch and

Sequencing
Basic batch and sequencing options are controller-based solutions that rely on
programming to manage the application.
Basic Coded (custom)

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

This includes both procedural (sequence) and formula (setpoint). These
generally are focused on independent, stand alone units (mixers, blenders,
reactors). However, these systems do not require a server and software such as
FactoryTalk Batch software for execution. This solution leverages the Logix
Batch and Sequence Manager application.
The Logix Batch and Sequence Manager application leverages the Logix5000
platform for control code and FactoryTalk View software for visualization. This
application is freely available as part of PlantPAx tools and applications. The
application enables local, single unit supervision and control, but supports
multiple, independent units in a single controller.
37
Chapter 4
The Logix Batch and Sequence Manager application does the following:
Offers configurable equipment definitions (phases, parameters, report
registers) and flexible recipe management (master/control recipe
definition) with HMI secured edits
Leverages standard ISA-88 models for control (state model, recipe model)
Offers connection to equipment through a bit interface or standard
PhaseManager interface
Supports ControlLogix controller redundancy
Features an intuitive runtime interface (If you choose FactoryTalk View
ME software on a PanelView Plus terminal, there is a limitation of a
12-inch or larger screen and 600 x 800 resolution or greater)
For the Logix Batch and Sequencing Manager application, see the Rockwell
Knowledgebase Answer ID 62366 at http://rockwellautomation.custhelp.com.
Comprehensive Batch and

Sequencing
Comprehensive
Chassis-based Server
Basic Configured
Logix Batch & Sequence Manager
Basic Coded
Custom Code
Comprehensive batch and sequencing solutions leverage core Logix functionality

(PhaseManager software) in conjunction with batch software (FactoryTalk Batch
software). PhaseManager software continues to be the basis for process control
code in the controller. FactoryTalk Batch software provides recipe management,
information management, process management, and unit supervision. The
comprehensive batch and sequencing options run on a server to manage the
application. The server can be an in-chassis module or an application server.
In-chassis Server
The in-chassis batch server is the Logix 56SAM-838 specialty module for a
ControlLogix system from Online Development, Inc. This solution is a local,
in-chassis option for running FactoryTalk Batch software. It eliminates the need
for additional server infrastructure and keeps batch control local to the process.
Target sizing for this module is less than five units.
38
Chapter 4
Application Server
Comprehensive
Application Server
The application server is the traditional FactoryTalk Batch solution. This

solution offers comprehensive batch management capability on a standard
application server. Traditional batch software and server solutions are required
for large or complex systems.
Comprehensive
Chassis-based Server
Basic Configured
Batch & Sequence Manager
Basic Coded
Custom Code
Table 27 - Batch Server Requirements

Attribute
Requirements, min
Application server
Operating system
Batch version 11 supports Windows 2008 Server operating system, 32-bit

Batch version 10 supports Windows 2003 Server operating system, 32-bit
Batch
Infrastructure
FactoryTalk Services Platform client

RSLinx Classic software
Additional
FactoryTalk Historian software

Batch Event Interface software
Batch System Status tool

3.0 GHz CPU
2 GB memory
UPS power backup recommended
FactoryTalk Batch server software

FactoryTalk Batch Equipment Editor software
FactoryTalk Batch Recipe Editor software
FactoryTalk Batch Client software
FactoryTalk Batch Archiver software
39
Chapter 4
Additional Capabilities
To complement the batch server, consider adding these additional capabilities to
your PlantPAx system.
Table 28 - Additional Batch Capabilities
Server
Description
FactoryTalk eProcedure software
Provides process management for manual operations:

Provides automated operator instructions for manual processes
Integrates manual instructions into automatic batch recipe execution
These are typical procedures that can be automated:
Manual batch execution and prompts
Complex standard operating procedures
Portable hand held applications
Product changeover and packaging line changes
Equipment startup and shutdown sequences
Abnormal condition handling
Cleaning and maintenance procedures
FactoryTalk Batch Material Manager software
Provides material management for batch manufacturing:

Provides an active material management and inventory system
Enables material-based phase definitions in batch execution
Enables just-in-time material and equipment selection for flexible batch manufacturing and
production scheduling
These are typical uses of the material management server:
Use as a standalone material management and inventory system
Provide interfaces for integrating in-house material inventory systems with plant production
processes
Integrate with material identification systems, such as barcode readers
Enable material-based phases if storage locations are flexible
Additional Tools
PlantPAx Batch tools and applications are available on the Rockwell Automation
Knowledgebase. For the specific PlantPAx Table of Contents, see Knowledgebase
Answer ID 62366 at http://rockwellautomation.custhelp.com.
These are the available batch tools.
Table 29 - Batch Tools
Tool
Description
Integrated visualization
(integrated visualization screens are added to the
PASS)
Offers configurable, pre-engineered FactoryTalk View graphics with embedded FactoryTalk Batch
components. See Knowledgebase Answer ID 62372:
Full-screen graphics
Pop-up graphics
Documented batch API code examples
Batch system status

(installed on the AppServ-Batch and graphics are
added to the PASS)
Integrates batch status information into the operator view. See Knowledgebase Answer ID 67642.
Batch reporting
(requires AppServ-Batch and
AppServ-Information Management)
Pre-configured, web-based batch reports. Deploy and run these reports through a standard web
browser or integrated VantagePoint portal. Create custom batch reports from existing templates.
See Knowledgebase Answer ID 62367.
The reports include the following:
Batch reports: batch listing, batch summary, batch detail
Material reports: material usage, forward tracking, backward tracking
Analysis reports: batch execution, duration comparison, batch exceptions
40
Chapter 4
Batch High Availability Options

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

- Standard, Redundant Hardware Options
and/or
- FactoryTalk Batch Warm Backup
Ethernet
ControlNet
with a PhaseManager
Application
41
Chapter 4
Notes:
42
Chapter
Process Information
PlantPAx process information relies on decision-making tools and dashboards to

provide both real-time and historical access to and analysis of process information
throughout the enterprise. There are two key areas of focus.
Table 30 - Strategic Product Management
Process Information Focus
Features
Data management
A distributed, data management strategy enables different focuses of data by various users:
Operator viewing data from the machine directly in the HMI
Supervisor viewing data to make plant-wide decisions
Manager viewing key KPIs from each plant and evaluating plant performance
Decision support
A decision support strategy addresses the need to rapidly capture and evaluate information to make
business decisions. This starts by efficiently and reliably collecting data and integrates the support
tools necessary to analyze, view, and summarize that data. Portals and dashboards are key to
presenting users the information they need, when they need it.
PlantPAx process information provides the right data at the right place at the
right time.
Topic
Page
Data Management
44
Decision Support
45
Information Management Server
46
43
Chapter 5
Process Information
Data Management
A data management strategy provides the following:

Distributed data collection to effectively collect and verify contextual
process data
Storage management to provide reliable and efficient data storage with
easy access
A data management strategy, considers overall system data:
Distributed historian collection and storage options
FactoryTalk Alarms and Events data
FactoryTalk Batch event data
A distributed historical-data management strategy offers localized, chassis-based,
high-speed data collection and recording, as well as site and enterprise solutions.
Table 31 - Distributed Historical Data Management Options

Type of Data
Requirements
Option
Time series
High-speed, on machine data collection

< 2500 tags
Embedded server module for ControlLogix chassis comes with

FactoryTalk Historian Machine Edition software already installed:
1756-HIST1 (1 GB) server module
1756-HIST2 (2 GB) server module
Continuous data buffer is compatible with FactoryTalk Historian SE
software, which allows the module to offload and forward that data
Longer term data storage

> 2500 tags
FactoryTalk Historian Site Edition software is a scalable process historian

that provides real-time access to reliable information:
Provides data capture, management, and analytical capabilities to
support decision-making.
Auto Discovery and Auto Configuration features reduce deployment
time and lower total cost of ownership
Aggregate data from multiple servers

Collect and store millions of data streams for
plant data across the enterprise
Support a central view of data
FactoryTalk Historian Enterprise Edition software is a multi-layer data

collection historian supports strategies where data historians are
required at any level from Line, Plant, Site, and all the way to Enterprise
deployments, such as regions, divisions, and other sub entities of a large
enterprise. Leverages the scalability and performance in the OSIsoft PI
technology.
Relational database
Select a Microsoft SQL server database to act as the central collection

point for event based data:
FactoryTalk Alarms and Events data
FactoryTalk Batch data
Event based
FactoryTalk Historian supports a complete redundant and highly available system

architecture.
Redundancy means no loss of data. Redundant interface nodes provide
data integrity. Each interface node consumes data points so the total
number of tags used must be doubled.
High availability means that you do not lose visibility to the collected data.
In order to accomplish this, you need redundant servers. Install several
historian servers in a Historian Collective and install two redundant
interface nodes for the collective per data source.
44
Process Information
Decision Support
Chapter 5
A decision support strategy provides the following:

Comprehensive view of plant operations to provide easy access to KPIs to
enable better business decisions
Presentation, analysis, and reporting to manage cost, quality, production,
assets, and resources more effectively
A decision support strategy incorporates these tools.

Table 32 - Decision Support Options
Option
Description
FactoryTalk VantagePoint and VantagePoint EMI

software
Web-based reporting software that brings all data together into a single decision support system:
All manufacturing data is accessible in real-time
Published reports, current dashboards, and real-time KPIs. viewable via web browser
Pre-configured reports, trends, and dashboards
Published reports are always current
FactoryTalk Historian ProcessBook software
Enable ProcessBook content (Standard ProcessBook displays, SQC view, batch view, alarm view) to
be hosted/displayed from within FactoryTalk View SE by using the Process Book Runtime.
Microsoft Excel add ins
Use Microsoft Excel software within the integrated environment to generate standard reports. Build
a report template once and re-use it as necessary.
Batch analysis
Integrated, predefined reports for batch data:

Product recipe batch records
System trending
Control loop performance
Predictive maintenance reports
Alarm reports
Integrated, predefined reports for alarm data:

Alarm distribution
Hourly alarm counts
Longest alarms
Most frequent alarms
Standing alarms
45
Chapter 5
Process Information
Information Management
Server
An information management application server is the central data point for

PlantPAx process information. FactoryTalk Historian and FactoryTalk
VantagePoint may be hosted on separate information management servers. The
same server requirements apply if they are hosted separately.
The information management application server offers these features:
Supports both data management and decision support
Manages several different data sets flows into the server
Supports data analysis from the server.
Table 33 - Information Management Server Requirements

Attribute
Requirements, min
Computer hardware
Operating system
Windows 2003 Server operating system (includes Microsoft Internet IIS with WWW service), 32-bit
Data management
FactoryTalk Historian server

SQL Server 2008 Express software (can be remote)
Microsoft reporting services
Decision support
FactoryTalk VantagePoint software
Infrastructure

RSLinx Classic software
Additional

Microsoft reporting services
Antivirus software
FactoryTalk VantagePoint Dashboard Builder (Xcelcius 2008) software
Concurrent or Named User client licenses
Data source connectors for databases and enterprise applications
46

3.0 GHz CPU
4 GB memory, min
UPS power backup recommended
Chapter
Advanced Process Control (APC) is an umbrella term that covers a wide range of
control technologies from simple regulatory loops to complex multi-unit
optimizations. Depending on the context, anything more sophisticated than a
simple PID loop can be considered APC.
The PlantPAx portfolio for APC provides a comprehensive set of tools and
solutions to optimize performance. This scalable framework lets you add the
tools you need:
Control regulatory loops, individual process units, and plant operations
Use modelling techniques to achieve more accurate and robust models
Pavilion 8 Dynamic Software
Standard
Logix5000
Instructions
Regulatory
Control
APC Function
Blocks and Fuzzy
Designer Software
Model Builder
Software
Inferential
Sensor
Advanced
Regulatory
Control
Model Predictive Control

and
Real Time Optimization
lue
sing Va
a
e
r
c
n
I
As you add advanced process control technologies, the technologies deliver more
value while becoming more complex.
Topic
Page
48
Fuzzy Designer
49
Soft Sensors
49
Model Predictive Control and Real-time Optimization
49
47
Chapter 6
There are two main categories for APC technologies: regulatory control and
supervisory control:
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.
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 include 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.
APC function blocks can be used in place of PID instructions for loops with long
dead-times and interacting loops.
The APC function blocks require RSLogix 5000 software:
Catalog number 9324-RLDAPCENE provides a license for use with one
Logix5000 controller.
Each additional controller requires a separate license, available as catalog
number 9324-RLDAPCCLENE.
Table 34 - Advanced Process Control Instructions

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
deadtime model.
Suitable for long deadtime 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 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.
48
Fuzzy Designer
Chapter 6
Fuzzy logic is useful when a well-tuned PID controller does not provide desired
response, but the expert knows from experience how to modify controller settings
on-the-fly. Fuzzy Designer software lets you convert expert know-how into a
control solution.
Table 35 - Fuzzy Designer Software

Software
Description
Fuzzy Designer software
Fuzzy Designer software (cat. no. 9324-RLDF24ENE) lets you define your fuzzy logic model, and
based on this model, generates an Add-On Instruction for Logix5000 applications. RSLogix 5000
software is required to use this Add-On Instruction.
RSLogix 5000 software
RSLogix 5000 software requires a license per workstation.
Soft Sensors
Soft sensors built with PlantPAx ModelBuilder can automatically predict product
quality parameters in real-time and provide backup or an alternative to analyzers
to generate feedback for mission-critical control systems:
ModelBuilder software provides offline data analysis and modeling.
SoftSensor Designer software converts models to Add-On Instructions.
Table 36 - Soft Sensors Software

Software
Description
PlantPAx ModelBuilder software
ModelBuilder software (cat. no. 9529-PPMDBENE) is an offline model building and analysis tool
that includes various analysis plots and a What-Ifs scenario tool to simulate future outcomes
based on different process scenarios to minimize risks and improve performance.
PlantPAx ModelBuilder with

SoftSensor Designer software
Models built with PlantPAx ModelBuilder (cat. no. 9529-PPMSBENE) can be converted into an
Add-On Instruction. This Add-On Instruction can be integrated with any of the advanced process
control technologies available from Rockwell Automation. These include model-based IMC, CC,
and MMC function blocks and custom supervisory control solutions developed by using Fuzzy
Designer and other tools. This option includes offline model building and analysis.
Model Predictive Control

and Real-time Optimization
The most common supervisory control technique is Model Predictive Control

(MPC), which can handle large multivariable processes and control these
product parameters while simultaneously optimizing the production process
through maximizing rates and yields, reducing raw material usage, minimizing
energy, and so forth.
The Pavilion8 software platform from Pavilion Technologies, a Rockwell
Automation company, is a modular software platform that includes modules to
control, analyze, monitor, visualize, warehouse, and integrate information. MPC
technology is an intelligence layer on top of basic automation systems that
continuously drives the plant to achieve multiple business objectivescost
reductions, decreased emissions, consistent quality, and production increases
every production minute.
49
Chapter 6
MPC technology continuously assesses current and predicted operational data,

compares them to desired results, and computes new control targets to reduce inprocess variability and improve process performance.
Console
Controller
Metrics
115
92
Soft
Sensors
64
70
50
39
33
25
10
10
13
Dynamic MPC
SCADA/HMI
Services
Control
Systems
MES
Systems
Custom
Database
Plant
Historians
SPC/SQC
Systems
Laboratory
Systems
Maintenance
Systems
Use the Pavilion platform within a PlantPAx system to add model predictive
control, environmental performance management, and production
performance management.
Table 37 - Software - Advanced Process Control Server Requirements
Attribute
Product
AppServ-APC

2/4 GHz CPU
2/4 GB memory
40 GB disk space
Windows XP, Windows 7, or 2008R2 operating system
Console Service software
Pavilion8 Application Server software
Control Server
Pentium III processor or better

500 MHz CPU
1 GB memory
40 GB disk space
Windows XP, Windows 7, or 2008R2 operating system
Pavilion8 Model Predictive Control software
50
Chapter
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.
PlantPAx 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 dont need.
Redundant Servers
NIC teaming on servers and clients.
Level 3 with dual Ethernet fiber

connections to Level 2 fiber
connections. For more information,
see page 53.
Device-level Ring
EtherNet/IP Network
Redundant I/O Modules
Topic
Page
High Availability Definition
52
High Availability Options
53
51
Chapter 7
High Availability Definition
The global process industry loses $20 billion, or 5% of annual production, due to
unscheduled downtime and poor quality, according to the ARC Advisory Group.
ARC estimates that almost 80% of these losses are preventable and 40% of the
preventable losses are due to operator effectiveness issues in the control room.
Availability is the probability that a system is operating successfully when needed.
Availability (A) is calculated by using this formula:
A = MTBF / (MTBF + MTTR)
where:
MTBF = Mean Time Between Failure
MTTR = Mean Time to Repair
Factors that affect maintainability include the following:
Diagnostics for detecting and isolating failures
Annunciation of faults
Troubleshooting tools
Trained personnel
Accessibility
Ability to add components or make changes online
Investing in a high availability system over simply an available one can make a
significant difference in lost time or costs seconds versus days or
hundreds versus millions of dollars. The average hour of plant downtime roughly
costs $12,500, but is substantially more at many continuous process plants,
according to ARC research. Using the $12,500 average, downtime for users with
99% availability can cost an estimated $1,050,000 per year, compared to just
$104 for users with 99.9999% availability.
Table 38 - Loss in Productivity Based on Possible Downtime
Availability Percentage
52
Possible Downtime per Year Estimated Cost per Year

(estimate $12,500/hr)
99%
3.5 days
$1,050,000
99.9%
9 hours
$112,500
99.99%
53 minutes
$11,000
99.999%
5 minutes
$1,000
99.9999%
30 seconds
$104
Chapter 7
High availability encompasses productivity, including reliability and

maintainability. Reliability is the likelihood that a device will perform its
intended function during a specific period of time. Maintainability is the ability
of a system to be changed or repaired.
System Element
Servers
The PASS and AppServ-HMI servers can be configured for redundancy of the following
software components:
HMI server
Alarm & Event server
Data server
The AppServ-Batch server supports different levels of fault tolerance.
For more information, see Batch High Availability Options on page 41.
PlantPAx supports off-the-shelf high availability options for servers from our encompass partner
Marathon Technologies or through virtualization by using VMWare's ESXi architecture.
Networks
The following applies for EtherNet networks:

NIC teaming on servers and workstation uses two physical Ethernet cards on each server
and workstation
Dual Ethernet media can connect the NIC cards to two separate level 2 switches
Dual Ethernet fiber media can connect the level 2 switches to separate switches on a
level 3 stack.
A Device-level Ring network can be used to connect the I/O racks and devices to your simplex
or redundant controllers.
The ControlNet network supports redundant media and adapters.
For more information, see Redundant Networks on page 18.
Controllers
ControlLogix controllers support enhanced redundancy on EtherNet/IP or ControlNet networks.

For more information, see Redundant Controller Hardware on page 15.
I/O modules
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 17.
Field devices
Redundant process network interfaces are available for PROFIBUS PA.

For more information, see PROFIBUS PA Devices on page 33.
See the PlantPAx Reference Manual, publication PROCES-RM001, for

additional redundant components and features, such as alarms and events.
53
Chapter 7
Notes:
54
Chapter
Critical Process Control and Safety Systems
With the combination of products from Rockwell Automation and ICS Triplex,
a Rockwell Automation company, the PlantPAx system supports expanded
process safety offerings that provide a high-level of fault tolerance, safety, and
critical process control.
Safety System
Development Workstation
(IsaGraph for TMR)
(RSLogix 5000 for ControlLogix)
TMR SIL 3 Safety

Controller and I/O
SIL 2 Controller for Fail Safe

or Fault Tolerance
Scalable Controller for SIL 2-3

and SIL Fail Safe and Fault
Tolerance
1400 Termination Board
Topic
Page
Process Control Safety System
56
ControlLogix SIL 1 and SIL 2 Systems
56
ICS Triplex SIL 2 and SIL 3 Systems
59
55
Chapter 8
Process Control Safety

System
Select safety equipment based on SIL requirements. For example, if your system
needs to continue running under a fault condition, you require process safety,
such as an ICS Triplex system. If a fault occurs and you want to shut down safely,
you select machine safety, such as a GuardLogix system.
ControlLogix SIL 1 and SIL 2

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

reputations. Safety Integrity Level certification makes it simpler, easier, and less
expensive to meet growing standards compliance requirements worldwide.
Common ControlLogix components and tools help customers lower lifecycle
costs for both process control and for separate, independent safety
instrumentation. The SIL 2 certification of ControlLogix products assures the
suitability of ControlLogix components, development tools, networks, and
databases for use in safety applications up to and including SIL 2.
Specific hardware, firmware revisions, and software versions 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.
56
Chapter 8
The following examples show ControlLogix configurations that meet SIL 1 and
SIL 2 certifications for fail safe and fault tolerant requirements.
Fault Tolerant Configuration

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

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

ControlLogix portion of the SIL 2 certified loop.
57
Chapter 8
Fail Safe Configuration

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

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

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

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

ControlLogix portion of the SIL 2 certified loop.
SIL Rated Instruments

Premier integration between ControlLogix systems and these Endress+Hauser
instruments includes integration documents, Add-On Instructions, and
faceplates.
Table 39 - SIL Rated Instruments
Product
Description
SIL 2 Endress+Hauser instruments
SIL 3 Endress+Hauser instruments
Cerabar S PMC71 pressure

Deltabar S PMD75 differential pressure
58
Promass 83 Coriolis mass flow

Prowirl 73 Vortex flow
Levelflex M FMP40 guided radar level
Micropilot M FMR240 radar level
iTEMP TMT182 temperature transmitter
Chapter 8
Additional Resources
Resource
Description
ControlLogix Selection Guide, publication 1756-SG001
ControlLogix system components
Using ControlLogix in SIL2 Applications Safety Reference Manual,

publication 1756-RM001
ControlLogix components supported in SIL 2 configurations
http://www.rockwellautomation.com/products/certification
Complete list of ControlLogix products that are certified for SIL 1 and SIL 2
applications
http://www.endress.com/eh/productDBs/homeDBs/en/home.nsf/contentvi Complete list of SIL rated instruments from Endress+Hauser

ew/13f258828d9b3eecc1256f690036d98e
ICS Triplex SIL 2 and SIL 3

Systems
ICS Triplex systems use a triple modular redundant (TMR) architecture. Triple
redundancy eliminates the possibility of any single component failure causing a
spurious or false trip. ICS Triplex integration with PlantPAx systems includes
OPC connectivity to FactoryTalk applications and CIP connectivity including
profile support in RSLogix 5000 software.
Both the Trusted and AADvance systems share a common Ethernet/IP network
within a PlantPAx system. In addition, the AAdvance system supports the CIP
producer/consumer communication protocol.
IsaGraph Development
Workstation
AADvance Safety
Control System
Trusted TMR
Control System
Table 40 - ICS Triplex Products

Product
Description
Trusted system
Trusted technology uses 3-3-2-0 fault-tolerant control to virtually eliminate spurious trips. Triple
modular redundancy (TMR) uses majority voting to identify a source of failure. Available with OPC or
CIP integration.
AADvance system
The AADvance technology is the following:

Configurable for SIL 2 and SIL 3
Scalable redundancy for fault tolerance
Simplex, duplex, or triplex configuration
ICS Triplex technology is available only as a complete system from ICS Triplex, a
Rockwell Automation company. For information, see http://www.icstriplex.com.
59
Chapter 8
Notes:
60
Chapter
The PlantPAx system infrastructure is built on open industry standards to

support seamless integration of the system components, as well as to provide
connectivity to higher-level business systems. In addition, the PlantPAx system
leverages best-of-breed technology partners where it makes sensedelivering
maximum value without relying on proprietary hardware and software.
Domain Controller
Topic
Page
Domain Controller
61
Ethernet Switches
62
62
A domain controller manages access to network resources (such as applications

and printers) for a group of users. Domain authentication, whether its 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 Ethernet nodes
(IP addresses).
The domain controller is a separate computer. Do not load any application
software on the domain controller. Load all system application software on
the other computers such as the PASS, application server, OWS, and EWS.
Microsoft support does not recommend running applications on the
domain controller, and certainly not applications that require more than
Authenticated User privileges to run.
The domain controller must be local to the system workstations and
servers (within the local firewall) and not remote to the system.
61
Chapter 9
Ethernet Switches
Infrastructure components that integrate enterprise, manufacturing, and

plant-floor environments include Ethernet switches.
Table 41 - Ethernet Switches

If
Then
Recommended Media
Supervisory
Routing information to other networks
Layer 3 switches
Stratix 8300
Cisco Catalyst 3760G or equivalent
Cisco Catalyst 3750 or equivalent
Fiber(1)
Connecting control hardware, sensors, and

workstations
Isolated networks
Layer 2 switches
Stratix 8000
Stratix 6000
Cisco Catalyst 2950 or equivalent
1585-series copper media
High availability at switch level
Layer 3 switch
Stackwise 3760G or equivalent
Fiber(1)
(1) For uplink cables between Layer 2-3, fiber is recommended for 1 GB connectivity.
These documents contain additional information.
Resource
Description
Converged Plantwide Ethernet (CPwE) Design and Implementation Guide,

publication ENET-TD001
Provides information on Ethernet security and firewalls.
Industrial Ethernet Media, Complete Solution for Ethernet Networks and

Integrated Architecture, publication 1585-BR001
Provides information on Rockwell Automation 1585 Ethernet cables.
Ethernet Design Considerations Reference Manual,

publication ENET-RM002
Explains the infrastructure components that allow this open network to

communicate seamlessly throughout a plant, from shop floor to top floor.
Region Locations for Panduit Corporation, Product category
Provides information on connected cabling systems and infrastructure

management from Encompass partner Panduit Corporation.
Cisco Ethernet-to-the-Factory, White paper c22-403859-02
Provides details on Cisco Ethernet-to-the-Factory (EttF) open architecture

for connecting real-time data from the production floor and information
from business applications.
Cisco switch information:

Cisco IE 3000 Series Switches
Cisco Catalyst 2960 Series Switches
Cisco integrated security solutions
Provides online resources for related products from Encompass partner

Cisco Systems, Inc.
62
Chapter
10
Migration Tools
Rockwell Automation provides a DCS migration program to assist customers

and integrators with migrating legacy DCS systems to PlantPAx systems.
Rockwell Automation works internally and with partners to develop tools and to
support migration and conversion projects. This program also works to develop
engineering competence and capacity within Rockwell Automation and its
partners for planning, executing, and supporting DCS migration projects.
Rockwell Automation supports the migration of these systems to
PlantPAx systems:
ABB (Bailey) Net90 and Infi90 control systems
Honeywell TDC 2000, TDC 3000, and TPS systems
Honeywell IPC620 programmable logic controllers
Emerson (Fisher Controls) PROVOX systems
Invensys (Foxboro) I/A systems
Rockwell Automation ProcessLogix (PLx) systems
For each system, there is a general migration plan that describes the particular
goals and methods for system migration, as well as specifics on the tools currently
available for migrating that system.
Other systems that Rockwell Automation has tools and services include
the following:
Emerson (Westinghouse) WDPF and WDPF II systems
NovaTech D/3 systems (original company (EMC Electronic Modules
Corp) and its technology (S/3 and D/3) went through multiple
acquisitions, including Rexnord, Banner, Texas Instruments, and GSE)
Siemens (Moore) APACS systems
Schneider (Square D originally, Crisp Automation) CRISP systems
Rockwell Automation provides extensive migration and integration capabilities
for PLC-based systems and other third-party systems.
63
Chapter 10
Migration Tools
Migration Tools
Migration tools take the following forms:

Products that become a part of the system during a migration, or may
become a permanent part of the target solution, such as I/O cables, I/O
scanners, and application codes
Utilities that assist with converting engineering information from the
original control system to a PlantPAx system, such as database conversion
utilities
Services that provide engineering and logistical support to migration
projects to assist with converting engineering configuration and
applications to the PlantPAx environment, such as manual database
conversions and operator graphics conversions
The following table presents a description of tools available for legacy DCS
migration support. Not all tools are available for each target legacy DCS system.
Table 42 - Migration Tools

System
Function
Tool
ABB
Bailey Net90 and Infi90
Communication
RoviSys OPC90 server
Honeywell
TDC2000 and TDC3000
Online Development RA56-cATM-BLY90 Bailey-to-Logix interface module

(1756 form factor; software preloaded)
Database conversion
Rockwell Automation Bailey database conversion utility
Faceplates
Rockwell Automation Bailey faceplate library
Application code
Rockwell Automation Bailey control strategy library (Add-On Instructions)
I/O interface
Rockwell Automation Bailey termination cables
Communication
Matrikon OPC server for Honeywell APP node
Database conversion
Rockwell Automation Honeywell database conversion utility
Application conversion and

simulation
Quest Honeywell MFC shadow module (ControlLogix application shadows a

MFC application)
I/O interface
Rockwell Automation IPC620 I/O scanner

Rockwell Automation TDC 2000 termination cables
Rockwell Automation TDC2000/3000 termination cables
ProSoft MVI56-DEM module (1756 form factor) integrates multiple
Honeywell DE smart instruments (including ST3000 smart pressure
transmitter) to ControlLogix sysem
Emerson
Fisher-Rosemount PROVOX
Communication
Matrikon PROVOX direct OPC server for Data Highway access via HDL
Online Development PROVOX Data Highway interface with RA56-SAM
module
Database conversion
Rockwell Automation PROVOX database conversion utility
Faceplates
Rockwell Automation PROVOX faceplate library
Application code
Rockwell Automation Emerson control strategy library (Add-On Instructions)
I/O interface
Quest PROVOX S10/S20 I/O scanner

Rockwell Automation PROVOX termination cables
64
Migration Tools
Chapter 10
Table 42 - Migration Tools

System
Function
Tool
Invensys
Foxboro IA
Communication
Matrikon Foxboro IA server

Online Development Foxboro IA Data Highway interface with RA56-SAM
module
Database conversion
Rockwell Automation Foxboro IA database conversion utility
Communication
Standard connections between ProcessLogix and PlantPAx systems
Database conversion
Rockwell Automation ProcessLogix database conversion utility
I/O interface
I/O is already Logix-based I/O
Siemens
Moore APACS
I/O Interface
Rockwell Automation APACS termination cables
Emerson
Westinghouse WDPF and WDPF II
I/O Interface
Rockwell Automation WDPF and WDPF II termination cables
Emerson
Rosemount RMV9000
I/O Interface
Rockwell Automation RMV9000 termination cables
ABB
Taylor MOD300 and Advant OCS
I/O Interface
Rockwell Automation I/O scanner interface for TRIO remote I/O
Rockwell Automation
ProcessLogix
Resource
Description
http://www.rockwellautomation.com/solutions/process
Or contact your local Rockwell Automation representative
General information about Rockwell Automation process capabilities. From the

left-hand menu on the home page, select DCS Migration Solutions for information
on the DCS migration program.
http://www.migratemyprocess.com/webinars
Prerecorded webinars on the DCS migration program and capabilities for process
customers.
Rockwell Automation Systems Solutions Business (also known as

the Manufacturing Process Solutions (MPS) group)
Rockwell Automation partner
Rockwell Automation TechSupport
DCS migration planning and project support. Through project experience and
recent acquisitions, Rockwell Automation has extensive expertise and experience
with legacy DCS and PLC migrations.
radcsmigrations@ra.rockwell.com
Email the Rockwell Automation DCS migration program.
http://www.rockwellautomation.com/solutions/process/
integrationdocs.html
Integration documents.
65
Chapter 10
Migration Tools
Notes:
66
Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and
application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the
best use of these tools.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect
support programs. For more information, contact your local distributor or Rockwell Automation representative,
or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual.
You can contact Customer Support for initial help in getting your product up and running.
United States or Canada
1.440.646.3434
Outside United States or

Canada
Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact

your local Rockwell Automation representative.
New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility.
However, if your product is not functioning and needs to be returned, follow these procedures.
United States
Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain
one) to your distributor to complete the return process.
Outside United States
Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document,
complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
Allen-Bradley, Rockwell Software, Rockwell Automation, LISTEN. THINK. SOLVE., PlantPAx, ControlLogix, CompactLogix, GuardLogix, FactoryTalk, Integrated Architecture, CENTERLINE, RSLinx, Logix5000,
RSLogix, RSNetWorx, ArmorBlock, ArmorPOINT, CompactBlock, FLEX Ex, FLEX, PowerFlex, IntelliCENTER, PhaseManager, ProcessLogix, Encompass,POINT I/O, Stratix 6000, Stratix 8000, Stratix 8300, and
TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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Publication PROCES-SG001D-EN-P - December 2011 68

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Selection Guide

PlantPAx Process Automation System

Selection Guide Scope

The PlantPAx Process Automation System is a defined set of standard Rockwell

PlantPAx System Overview

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

Selection Guide Scope

PlantPAx Process Automation System

System high availability

Device integration and asset management

Batch and sequencing control

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

Selection Guide Scope

These documents contain additional information concerning related products from

Table 1 - Additional Documentation

1756 ControlLogix Controllers Technical Data,

Contains specifications for ControlLogix controllers.

PlantPAx Process Automation System Reference

Provides recommendations for implementing a PlantPAx Process Automation system.

EtherNet Design Considerations Reference

Converged Plantwide EtherNet (CPwE) Design

Ethernet Design Considerations Reference

ControlNet Media System Components List,

Describes the ControlNet network media components.

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

Process System Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PlantPAx System Release 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Availability Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Process Control Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PlantPAx System Overview

The PlantPAx system represents the Rockwell Automation culmination of

Optional Safety System

TMR SIL 3 Safety

Remote I/O Racks

SIL 2 Safety Controller

Classic I/O / HART

Classic I/O / HART

Intrinsically Safe Area

Field Device Networks

Intrinsically Safe Area

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

PlantPAx System Overview

The PlantPAx system focuses on these main areas.

Field device integration and

Batch management and control

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

Critical process control and safety

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

PlantPAx System Overview

Process System Elements

A PlantPAx system is built on these system elements (combinations of hardware

Table 2 - System Elements

Process automation system server (PASS)

Operator workstation (OWS)

Engineering workstation (EWS)

HMI application servers provide additional system capacity, as needed.

Independent workstation (IndWS)