Allen-Bradley PlantPAx User manual

PlantPAx Distributed Control System

Selection Guide

Original Instructions

PlantPAx Distributed Control System Selection Guide

The PlantPAx® system provides a modern approach to distributed control. The system shares common technology (Integrated Architecture® system) with all other automation disciplines in the plant. This approach creates a seamless information flow across the plant for optimization opportunities and enables a Connected Enterprise. Our scalable platform provides you with the flexibility to implement a system appropriate for your application.

What’s Inside

This revision of the PlantPAx Selection Guide updates system rules to support the latest characterized products.

Topic Page

PlantPAx topology updates for System Release 5.0 12 ControlLogix® and CompactLogix™ process controllers 35 Online addition of module and connection types 39 Overview of analytics options 47

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description System Core

PlantPAx Distributed Control System Configuration and Implementation User Manual, publication PROCES-UM100

Rockwell Automation Library of Process Objects, publication PROCES-RM200

PlantPAx Hardware Specifications and Certifications, publication PROCES-SR027 Process Automation System Training Curriculum, publication PROCES-CA001 Describes the courses that are available for a better understanding of the

http://www.rockwellautomation.com/solutions/process Provides general information about Rockwell Automation process capabilities. From the

http://www.migratemyprocess.com/webinars

Product Compatibility and Download Center at

https://compatibility.rockwellautomation.com/Pages/home.aspx

Infrastructure

PlantPAx Template User Manual, publication 9528-UM001 Describes the catalog numbers and details for using virtual image templates to configure

Stratix Ethernet Device Specifications Technical Data, publication 1783-TD001 Contains product specifications, certifications, and catalog numbers for Ethernet switch

Converged Plantwide Ethernet (CPwE) Design and Implementation Guide, publication ENET-TD001

Product Compatibility and Download Center at

https://compatibility.rockwellautomation.com/Pages/home.aspx

Field Device Integration

Integrate E+H Instruments in a PlantPAx System Integration Document, publication PROCES-SG003

http://www.endress.com Products from Endress+Hauser. Encompass™ partners

Provides procedures to configure infrastructure components for your PlantPAx system.

Provides information on how to use the Process library, including the PlantPAx Instructions and display elements.

Provides information on PlantPAx system hardware specifications and certifications.

PlantPAx system.

menu bar, select Support> Modernization Support for DCS migration information. Features prerecorded webinars on the DCS migration program and capabilities for

process customers. Website helps you find product-related downloads including firmware, release notes,

associated software, drivers, tools, and utilities.

virtual machines.

devices. Provides information on Ethernet security and firewalls.

Website helps you find product-related downloads including firmware, release notes, associated software, drivers, tools, and utilities.

Provides pre-engineered, pre-tested, supported, and maintained integrated solutions for plant-wide diagnostics and lifecycle management.

Provides information on connected cabling systems and infrastructure management from Encompass™ partners.

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Scalable

Architectures

System Infrastructure

• Traditional infrastructure

• Virtual infrastructure

• VMware requirements

•Network topologies

• Ethernet switches

Servers and Workstations

•PASS servers

• Engineering workstations

•Operator workstations

• Independent workstations

•Application servers

• Domain controllers

Controllers, Field Networks, and I/O

•Simplex controllers

•Redundant controllers

• Skid-based controllers

•I/O products

•Process network I/O

• Motor Control devices

Application-Specific Options

•

Analytics

• Process Safety Systems

Select a PlantPAx System

Welcome and thank you for choosing the PlantPAx Distributed Control System. The PlantPAx system is an integrated control and information solution that provides plantwide optimization for a wide range of industries. This single-platform system is built on open industry standards to help support the seamless integration of system components, and to provide connectivity to high-level business systems.

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A PlantPAx system consists of these system elements.

Table 1 - System Element Descriptions

System Element Description

Process Automation System Server (PASS) The PASS is a required system element that can host displays, alarms, and data connections to controllers.

Operator workstation (OWS) and Application server (AppServ-OWS)

Engineering workstation (EWS) and Application server (AppServ-EWS)

AppServ-Asset management The asset management server acts as a centralized tool for managing automation-related asset information

AppServ-Batch The batch application server provides comprehensive batch management, including unit supervision, recipe

AppServ-Info (Historian, VantagePoint®, SQL) Data management storage can include a Historian or SQL server. There are three different types of

Controllers The ControlLogix and CompactLogix controllers support continuous process and batch applications. These

Independent workstation (IndWS) The independent workstation acts as a PASS, EWS, and OWS for single-station systems

Domain controller A domain controller is a server that manages security authentication requests within the Windows® server

Multiple PASS servers can be used to provide additional system capacity or to create logical segregation of application content that is based on the process.

For smaller systems, the PASS - C (consolidated PASS server) supports functions that otherwise would be hosted on application servers.

The OWS and AppServ-OWS provides an interactive graphical interface to monitor and control the process. The AppServ-OWS uses Microsoft® Remote Desktop Services (RDS) technology to serve multiple instances of the OWS as thin clients from one server. The technology provides for FactoryTalk® View SE thin clients that run applications and process data on a remote computer.

The EWS and AppServ-EWS provides a central location for configuring the system and monitoring/maintaining system operation. The AppServ-EWS uses Microsoft Remote Desktop Services (RDS) technology to serve multiple instances of the EWS as thin clients from one server. The technology provides for FactoryTalk View SE thin clients that run applications and process data on a remote computer.

(both Rockwell Automation and third-party assets). The asset management application server includes capabilities for asset inventory, source control, audits, change notifications, reporting, and security.

management, process management, and material management. The batch application server can be linked with visualization elements on the OWS and configuration clients on the EWS.

AppServ-Info servers depending on the function that is being provided: FactoryTalk® Historian software, FactoryTalk® VantagePoint® software, and the SQL server.

controllers also support discrete and motion applications.

(independent class).

domain. PlantPAx uses a domain controller to store user account information, authenticate users, and enforce security policies.

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Scalable Architectures

Distributed Architecture - Single to Multiple PASS Servers

Skid/ Station Architecture

Distributed Architecture - Single PASS Server

Rockwell Automation characterizes the PlantPAx system that is based on its size or architecture class. A ‘characterized’ (system-tested) classification yields system performance data and recommended hardware and software configurations. The classes of PlantPAx architecture offer system scalability while organizing Integrated Architecture® products consistent with process industry expectations.

The architecture classes include the following:

Consideration Skid or Station Architecture

(small < 2000 I/O)

FactoryTalk® Directory Place FactoryTalk Directory on the

station

PASS Single station serves as PASS and

OWS in an independent workstation.

EWS 1 EWS required; provided separately Included within PASS-C image • 1 EWS required

OWS (clients) Provided separately via independent

workstation

Controller 1…5 CompactLogix or ControlLogix 1…5 CompactLogix or ControlLogix ControlLogix Architecture

Distributed Architecture

PAS S-C

(small < 2000 I/O)

Place FactoryTalk Directory on the PASS-C

One PASS-C that includes:

• FactoryTalk Directory server

•HMI server

• Data server

• Alarm and Event server

•EWS / OWS The PASS-C supports functions that would otherwise be hosted on separate application servers. The PASS-C single computer also hosts:

•FactoryTalk Historian

• AppServ-Asset Management

• AppServ-VantagePoint

• AppServ-Info (SQL)

Maximum 10 OWS clients • Can have as many as 120 OWS

Distributed Architecture

Single or Multiple PASS

(medium= 2,000…10,000 I/O)

Place FactoryTalk Directory on its own PASS

One PASS that includes:

•HMI server

• Data server (as many as 2 per PAS S)

• Alarm and Event server

Additional PASS, as needed (as many as 10 servers or redundant server pairs).

• Can have as many as 5 EWS that are active and in use

• Additional AppServ-EWS as needed

clients

• Additional AppServ-OWS as needed

Distributed Architecture

Single or Multiple PASS

(large = 10,000+ I/O)

Place FactoryTalk Directory on its own PASS

One PASS that includes:

•HMI server

• Data server (as many as 2 per PAS S)

• Alarm and Event server

Additional PASS as needed (as many as 10 servers or redundant server pairs)

•1 EWS required

• Can have as many as 5 EWS that are active and in use

• Additional AppServ-EWS as needed

• Can have as many as 120 OWS clients

• Additional AppServ-OWS as needed

Application Servers Not applicable

• In-chassis historian and in-controller batch are available.

• Can be integrated into a distributed architecture.

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Actual count varies depending on application requirements. There is no hard limit to the number of controllers. The number of controllers that can be supported per PASS (data server) depends on controller selection, controller load, and number of OWS.

Included within PASS-C image • AppServ-Batch as needed

• AppServ-Info (FactoryTalk Historian or FactoryTalk VantagePoint®) as needed

• AppServ-Batch as needed

• AppServ-Info (FactoryTalkHistorian or FactoryTalkVantagePoint) as needed

Select a PlantPAx System

Consideration Skid or Station Architecture

AppServ-Asset Not applicable.

AppServ-Info (SQL) Not applicable

Recommended Compute Platform

(small < 2000 I/O)

If attached to a PlantPAx DCS, make sure FactoryTalk® AssetCentre can access the skid assets

If attached to a PlantPAx DCS, make sure FactoryTalk AssetCentre can access the skid assets

• VersaView® 6181 or similar compact personal computer

• Stratus zTC 100i

Distributed Architecture

PAS S-C

(small < 2000 I/O)

Included within PASS-C image AppServ-Asset (FactoryTalk

Included within PASS-C image Place the AppServ-Info (SQL) on its

• Traditional physical infrastructure hardware

• Stratus zTC 110i- Virtual

Distributed Architecture

Single or Multiple PASS

(medium= 2,000…10,000 I/O)

AssetCentre) is required

own computer

• VersaVirtual™ 2000 Appliance

• E-2000 or E-3000 Industrial Data Center

Distributed Architecture

Single or Multiple PASS

(large = 10,000+ I/O)

AppServ-Asset (FactoryTalk AssetCentre) is required

Place the AppServ-Info (SQL) on its own computer

• VersaVirtual 2000 Appliance

• E-2000 or E-3000 Industrial Data Center

PlantPAx System Estimator

Rockwell Automation offers the PlantPAx System Estimator tool as part of the Integrated Architecture® Builder software. The System Estimator tool lets you define your PlantPAx system and verifies that your architecture and system elements are sized properly.

The System Estimator tool provides helps you select system elements and size the system. The sizing guidelines are based on the rules and recommendations from PlantPAx system characterization to achieve known performance and reliability.

The following items are created based on your inputs:

• Supervisory Ethernet network with all servers, operator, and engineering workstations and controller chassis

• List of required software catalog numbers

• List of network components per subsytem

• List of controllers, I/O, and process devices

After selecting the system elements as defined in this guide, use the PlantPAx System Estimator tool to modify their properties. You can then create a bill of materials (BOM) with the Integrated Architecture Builder software. The BOM includes controllers, I/O, networks, drives, devices, and software products that comprise your Distributed Control System.

To access the Integrated Architecture Builder software to use the PlantPAx System Estimator tool, download the Product Selection Toolbox™

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Select a PlantPAx System

Software Release Information

Performance guidelines are based on the use of the software versions listed. For new PlantPAx systems, we recommend that you use these versions of software.

• Studio 5000 Logix Designer® application, version 33

• Studio 5000® Application Code Manager, version 4

• FactoryTalk® View software, version 12

• FactoryTalk® Batch software, version 14

• FactoryTalk AssetCentre software, version 10

• FactoryTalk VantagePoint software, version 8

• FactoryTalk Historian software, version 7

For the latest compatible software information, see the Product Compatibility and Download Center

PlantPAx System ID

The PlantPAx System ID is a unique identifier that helps simplify the management of your system over its lifecycle. The System ID creates a record of the installed products in your system and provides a dashboard that shows the hardware lifecycle status, notifications of updates and patches, and compatibility information. Use this information to:

• Plan spare and replacement parts to better size inventory

• Define the boundaries of the system

• Plan when and where to implement system upgrades

Your System Integrator uses the Asset Inventory Agent within a FactoryTalk AssetCentre project to generate a system inventory file. Before delivering your system, your System Integrator registers your System ID with Rockwell Automation and provides you directions on how to access your MyEquipment portal.

The System ID is only available if you purchase a PlantPAx PASS Bundle. The PlantPAx PASS Activation serial number is the System ID.

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PlantPAx PASS Large Bundle (Perpetual)

This software bundle provides the core software for PlantPAx DCS systems. The PlantPAx System ID is integrated into the bundle. Additional assets can be added under recommended products. To support large systems, this bundle has an unlimited HMI server and asset management included.

PlantPAx Catalog Number Component Catalog Number Description Support Options

9701-VWSS000PE FT View SE Server Unlimited

9528M-PAXPASST11

9515-FTACBASEPE AssetCentre Base Perpetual

9515-FTACTIAENTP FT AssetCentre InventAgent

9528-PAXPASSPE PlantPAx PASS Activation (System ID)

Electronic Media or Physical Media

8x5 Support

24x7 Support

PlantPAx PASS Medium Bundle (Perpetual)

This software bundle provides the core software for PlantPAx DCS systems. The PlantPAx System ID is integrated into the bundle. Additional assets can be added under recommended products. To support mid-sized systems, the HMI server is capable of supporting 250 displays and asset management is included.

PlantPAx Catalog Number Component Catalog Number Description Support Options

9701-VWSS250PE FT View SE Server 250

9528M-PAXPASST21

9515-FTACBASEPE AssetCentre Base Perpetual

9515-FTACTIAENTP FT AssetCentre InventAgent

9528-PAXPASSPE PlantPAx PASS Activation (System ID)

Electronic Media or Physical Media

8x5 Support

24x7 Support

PlantPAx PASS Small Bundle

This software bundle provides the core software for PlantPAx DCS systems. PlantPAx System ID is integrated into the bundle. Additional assets can be added under recommended products. To supporter smaller sized systems, the HMI server is capable of supporting 100 displays and asset management is included.

PlantPAx Catalog Number Component Catalog Number Description Support Options

9701-VWSS000PE FT View SE Server 100

9528M-PAXPASST31

9515-FTACBASEPE AssetCentre Base Perpetual

9515-FTACTIAENTP FT AssetCentre InventAgent

9528-PAXPASSPE PlantPAx PASS Activation (System ID)

Electronic Media or Physical Media

8x5 Support

24x7 Support

Recommended Products

8x5 Support 24x7 Support

Catalog Number Description Catalog Number Description

9515M-FTACRT11 FactoryTalk AssetCentre 100 Assets Add On 9515M-FTACRT12 FactoryTalk AssetCentre 100 Assets Add On

9515M-FTACRT101 FactoryTalk AssetCentre Disaster Recovery - Rockwell Automation 9515M-FTACRT102 FactoryTalk AssetCentre Disaster Recovery - Rockwell Automation

9518M-HSERT11 FactoryTalk Historian SE 1,000 Tag Add-On 9518M-HSERT12 FactoryTalk Historian SE 1,000 Tag Add-On 9701M-VWSDRT11 FactoryTalk View SE Client 9701M-VWSDRT12 FactoryTalk View SE Client 9701M-VWSDRT41 FactoryTalk SE Unlimited Redundant Server Option 9701M-VWSDRT42 FactoryTalk SE Unlimited Redundant Server Option 9701M-VWSDRT51 FactoryTalk SE 250 Redundant Server Option 9701M-VWSDRT52 FactoryTalk SE 250 Redundant Server Option 9701M-VWSDRT61 FactoryTalk SE 100 Redundant Server Option 9701M-VWSDRT62 FactoryTalk SE 100 Redundant Server Option

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System Infrastructure

vSphere Management: vSphere Client (Desktop)

Engineering: vSphere Client/Remote Desktop

Office: Remote Desktop (Tablet)

Redundant Switches

Physical Hosts with ESXi

Storage Array (Ethernet/Fiber

Virtual Machines

When building your system, you must decide whether your server and client workstations are in a virtual or traditional environment. Traditional, for our purposes, means one operating system (OS) that is natively on one computer. Virtual machines are hardware independent; not tied directly to a specific hardware or OS.

Traditional Infrastructure

In a traditional infrastructure, each server and workstation is installed on its own physical machine. Software and hardware updates are performed on each server and workstation individually. In addition, there is a conventional relationship between switch ports and servers ports and a standard network management.

Rockwell automation offers the following traditional templates. For all other system elements, you install your operating system and software directly on the physical computer.

Table 2 - Installation Files on USB Devices

System Element Cat. No. Description

PASS - C (consolidated) 9528-PASSCENM USB device contains a bootable image to install a consolidated PASS on a physical machine. The PASS-C includes

Historian, VantagePoint, Asset Management, OWS, and EWS. The end user is responsible for acquiring the appropriate Microsoft OS license for Server 2016. A Rockwell Automation license is required for software activation.

OWS ISO 9528-OWSISOENM USB device contains a bootable image to install an operator workstation on a physical machine. The end user is

responsible for acquiring the appropriate Microsoft OS license for Windows 10. A Rockwell Automation license is required for software activation.

Virtual Infrastructure

Virtualization breaks the dependency between operating system and physical hardware. Multiple virtual machines (VMs) can run different operating systems and applications from various locations on the same server. You can upgrade hardware without stopping your operation or replacing the operating system on the server or workstation system elements, thus reducing downtime and maintenance costs.

A VM behaves exactly like a physical computer because the VM contains its own ‘virtual’ CPU, RAM, hard disk drive, and network interface card. The VM runs as an isolated guest OS installation.

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System Infrastructure

Table 3 - Virtual Infrastructure Components

Model Type Description

Industrial Data Center

• E-2000 supports 2 host servers

• E-3000 supports 3 host servers

VersaVirtual Appliance

• VersaVirtual 1000 supports 1 host server

• VersaVirtual 2000 supports 2 host servers

The Industrial Data Center (IDC) is a centralized hub for hosting virtual servers and workstations. The IDC pre-assembled unit includes on-site commissioning of your system by a Rockwell Automation representative.

Each IDC is in a cabinet (19 in.) that includes host servers and the following:

• Rockwell Automation support

•1 management server

• Software defined storage

• VMware vSphere standard

• VMware vCenter standard

• Redundant server access switches

• Virtual machine backup solution For purchase information, contact your local distributor or Rockwell Automation sales representative. Provide the

representatives with a list of applications that you plan to deploy in an IDC.

For more information, see the Industrial Data Center Product Profile, publication GSMN-PP001. The VersaVirtual Appliance is a hyperconverged (compute, networking, and storage) appliance for entry-level

virtualization in a managed environment. One server can run multiple operating systems. The appliance can support as many as 15 applications.

Each application includes the host server(s) and the following:

• Rockwell Automation support

• Pre-engineered and configured virtualization software

• 1 management server (VersaVirtual 2000 only)

• Software defined storage (VersaVirtual 2000 only)

• VMware vSphere standard

• VMware vCenter foundation

• 2x10G copper uplink ports

Optional items:

• Expands up to 10 physical servers

• UPS or redundant UPS

• Thin clients

For more information, see VersaVirtual Appliance.

Stratus ztC Edge

•Stratus ztC Edge 110i

• Stratus ztC Edge 100i

ztC Edge from Stratus brings the benefits of virtualization and fault-tolerant computing to the industrial edge. Rugged, hot-swappable nodes can deploy on DIN rails inside the control cabinet. Run a PASS-C and ThinManager® on the ztC Edge to form a solution-in-a-box for smaller locations.

For purchase information, contact your distributor.

For more information, see ztC Edge

Rockwell Automation offers virtual image templates as an option to deploy the PlantPAx distributed control system. The PlantPAx Virtual Image Templates deliver the core system elements as pre-configured, drop-in templates. For ease of operation and to help reduce cost, each single virtual image template can be reused.

Table 4 - Virtual Image Templates on USB Devices

Virtual Template Cat. No. Description

PASS 9528-PASSVTENM USB device contains the virtual image template for the PASS. The end user is responsible for acquiring the appropriate

Microsoft OS license for Server 2016. All required Rockwell Automation software is pre-installed but not activated.

EWS 9528-EWSVTENM USB device contains the virtual image template for the EWS. The end user is responsible for acquiring the appropriate

Microsoft OS license for Windows 10. All required Rockwell Automation software is pre-installed but not activated.

OWS 9528-OWSVTENM USB device contains the virtual image template for the OWS. The end use is responsible for acquiring the appropriate

AppServ-OWS, AppServ-EWS 9528-APPXWSENM USB device contains the virtual image template for AppServ-OWS and AppServ-EWS. The end user is responsible for

AppServ-Info (Historian) 9528-APPHISENM USB device contains the virtual image template for AppServ-Info (Historian). The end user is responsible for acquiring the

AppServ-Asset 9528-APPASMENM USB device contains the virtual image template for AppServ-Asset. The end user is responsible for acquiring the

Microsoft OS license for Windows 10. All required Rockwell Automation software is pre-installed but not activated.

acquiring the appropriate Microsoft OS license for Server 2016. All required Rockwell Automation software is pre-installed but not activated. You must purchase the appropriate Windows CAL from a Microsoft distributor.

IMPORTANT: Each client needs an RDS CAL license.

appropriate Microsoft OS license for Server 2016. All required Rockwell Automation software is pre-installed but not activated.

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System Infrastructure

Table 4 - Virtual Image Templates on USB Devices

Virtual Template Cat. No. Description

AppServ-Info (SQL) 9528-APPSQLENM USB device contains the virtual image template for AppServ-Info (SQL). The end user is responsible for acquiring both the

appropriate Microsoft OS license for Server 2016 and Microsoft SQL Server.

AppServ-Info (VantagePoint) 9528-APPVTPENM USB device contains the virtual image template for AppServ-Info (VantagePoint). The end user is responsible for acquiring

the appropriate Microsoft OS license for Server 2016. Most required Rockwell Automation software is pre-installed but not activated. The FactoryTalk VantagePoint software is not pre-installed for your convenience.

AppServ-Batch 9528-APPBATENM USB device contains the virtual image template for AppServ-Batch. The end user is responsible for acquiring the

appropriate Microsoft OS license for Server 2016. Most required Rockwell Automation software is pre-installed but not activated. The FactoryTalk Batch software is not pre-installed for your convenience.

Domain controller 9528-PADCVTENM USB device contains the virtual image template for a Domain controller. The end user is responsible for acquiring the

appropriate Microsoft OS license for Server 2016. You must purchase the appropriate quantity of Windows CALs from a Microsoft distributor.

Each template USB device includes one OS system for each applicable type. If you are considering virtualization, we suggest that you visit the Rockwell Automation Industrial Networks website, at

https://www.rockwellautomation.com/en_NA/capabilities/industrial-networks/overview.page?

Template Distribution

Obtain PlantPAx virtual image templates by the following methods:

Media -- Order a physical copy of the virtual image template. Only the latest virtual image templates are available via physical media. The end user is responsible for acquiring the appropriate Microsoft OS license for Server 2016 or Windows 10.

Electronic Software Delivery (ESD) -- You must purchase licensed media before downloading an electronic copy of the virtual image template from the Product Compatibility and Download Center (PCDC) website. The latest and previous versions of the virtual image templates are available for download from the PCDC.

For additional information, see the PlantPAx Template User Manual, publication 9528-UM001

VMware Component Requirements

The VMware vCenter server provides a centralized platform for managing your VMware vSphere environments. The virtual desktop and virtual server require resources from the physical infrastructure to operate. When you purchase hardware, consider future expansion plans by adding an additional 20…30% of resources. VMware makes it simple to scale the system size upward by adding servers in the future to provide additional resources.

Remember to divide the total system requirements by the minimum number of servers that are required to run the system at any given time. For example, with a three-server system that uses VMware fault tolerance or high availability, you divide by two. This type of calculation makes sure that the system can continue to run with two servers if one server fails.

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System Infrastructure

VMware Sizing

Virtual Machines are limited by the CPU megahertz of the physical core. A common misconception is that a VM can use as much CPU megahertz as needed from the combined total available. One vCPU VM never uses more megahertz than the maximum of one CPU/core. If a VM has two vCPUs, it never uses more megahertz than the maximum of each CPU/core.

Table 5 - CPU and PlantPAx Resource Requirements

Server and Workstation Type vCPU vRAM (GB) vHardDisk (GB)

Process Automation Domain Controller (PADC) 1 4 40 Process Automation System Server (PASS) 4 16 60 Operator Workstation (OWS) 2 4 40 Engineering Workstation (EWS) 2 8 100 Operator Workstation Application Server (AppServ-OWS) 8 16 60 Engineering Workstation Application Server (AppServ-EWS) 4 16 100 Information Management Application Server Historian (AppServ-Info Historian) 2 4 120 Information Management Application Server VantagePoint (AppServ-Info VantagePoint) 2 4 60 Information Management Application Server SQL (AppServ-Info SQL) 2 4 120 Asset Management Server (AppServ-Asset) 2 4 60 Batch Management Server (AppServ-Batch) 2 4 60 VMware vCenter Server 2 4 40 System Reservation (specify percent to be reserved) 10 —

Reference Network Topologies

PlantPAx reference topologies take advantage of converged architectures, that support:

• Access to device webpages throughout the architecture

• Full visibility to the network via tools such as FactoryTalk® Network Manager™

• Access to the data in smart process devices from outside the local network

These reference topologies include:

• Example 1: Redundant PRP Topology

• Example 2: Resilient DLR Topology

• Example 3: Simplex - Star Topology

• Example 4A: PRP Skid and MCC Lineup

• Example 4B: DLR Skid and MCC Lineup

• Example 4C: Simplex Skid and MCC Lineup

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System Infrastructure

Application Servers (redundant)

Cisco 9300 (stacking)

Stratix 5400 or 5410

Stratix 5400

LAN A LAN B

Redundant Controllers

I/O Rack

Supervisory Network Control Network

Layer 3 Routed

Trunk - (Native

HSRP (Configuration

Secondary Logix

EtherChannel RedBox (PRP) LAN-A / LAN-B

Cisco Stack

Stratix 5700

Stratix 5400

MCC

Operator and Engineering Workstations

Example 1: Redundant PRP Topology

Redundant PRP topology is used for critical operations, and includes infrastructure duplication, multiple fault tolerance capability, zero recovery time within the PRP zone, and minimal recovery time for traffic leaving the PRP zone. Redundant PRP recommendations include:

• 10 controllers per topology (pair of redundant Redboxes)

• In a redundant Redbox configuration, do not connect anything other PRP and uplink ports

• Ports in the PRP channel group cannot be configured for other resiliency protocol, such as DLR or Resilient Ethernet Protocol (REP).

Table 6 - Properties of Example 1 Architecture

Redundant PRP Topology

Why would I select this architecture?

Most robust option for operations that require high availability. PRP requires double the cabling and components to establish no single point of failure. For a true no single point of failure capabilities, PlantPAx recommends redundant power sources along with separate physical paths for media.

What protocols does it use?

• Implementation of EtherChannel for hardware redundancy between servers and workstations

• EIGRP (Enhanced Interior Gateway Routing Protocol) provides Layer 3 routing capabilities

• HSRP provides redundant PRP ‘RedBox’ functionality

• PRP provides dual connectivity between two devices

• RedBox (redundancy box) is a switch with PRP technology that connects devices without PRP technology to both LAN A and LAN B

• Cisco® Catalyst® 9300 or 3850 stack switches

• Redundant application servers via physical or virtualized environments

• Pair of Layer 3 PRP enabled Stratix® switches:

What components do I need?

• Duplicate LAN A/B Layer 2 infrastructure switches:

• Non-PRP devices require Stratix 5400 switch to enable VDAN support

• 1756 and 5094 I/O families support PRP

– Stratix 5410 (used if GPS, multiple PRP channels, rack-mount format, or AC power is required) –Stratix 5400

–Stratix 5400 –Stratix 5700

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System Infrastructure

MCC

Operator and Engineering Workstations

Application Servers (hypervisor)

Secondary ControllerPrimary Controller

1715 Redundant I/O

Field Devices

Cisco 9300 (stacking)

Stratix 5400

Stratix 5700

EtherChannel Cisco Stack DLR Gateway

Supervisory Network Control Network

Layer 3 Routed

Trunk - (Native

HSRP (Configuration

Secondary Logix

Example 2: Resilient DLR Topology

Resilient DLR topology helps prevent communication loss between devices if a fault occurs. Multiport devices (embedded EtherNet/IP™ ports) equipped with DLR technology connect directly to neighboring nodes and form a ring topology at the end devices. If a break in the network is detected, the network provides an alternate forwarding path for the data to help recover the network. DLR recommendations include:

• 10 controllers per topology

• In a dual gateway configuration, do not connect anything other DLR and uplink ports

• Maximum of 50 switch nodes per ring

• Single VLAN per ring

• PlantPAx does not recommend DLR trunking or DLR DHCP

• Place at least 1 meter of cable between each DLR device

Table 7 - Properties of Example 2 Architecture

Resilient DLR Topology

Why would I select this architecture?

This architecture provides a means to detect, monitor, manage, and recover from one fault ring-based network. You can use redundant gateways to provide DLR network resiliency to the rest of the network.

• Implementation of EtherChannel for hardware redundancy between servers and workstations

What protocols does it use?

• EIGRP (Enhanced Interior Gateway Routing Protocol) provides Layer 3 routing capabilities; this protocol is used within the Cisco Catalyst switches

• DLR is a ring topology that recovers after one point of failure (3 msec or less)

• Cisco Catalyst 3850, 9300 stack switches

• Redundant application servers via physical or virtualized environments

What components do I need?

• DLR gateway capable switches (if you need multiple rings, use a Stratix 5400 or 5410 switch)

• DLR capable Stratix switches

• DLR capable Ethernet modules

14 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Check I/O device specifications to verify DLR support.

System Infrastructure

Field Devices

Primary Controller

Operator and Engineering Workstation

ControlLogix I/O

Application Server

Cisco 9300 (stacking)

Stratix 5700

Supervisory Network Control Network

Trunk - (Native

Example 3: Simplex - Star Topology

Simplex - Star topology features single network connections throughout the topology. There is no redundancy so connected nodes cannot communicate on the network if there is a network failure.

Table 8 - Properties of Example 3 Architecture

Simplex - Star Topology

Why would I select this architecture?

What protocols does it use?

What components do I need?

This architecture provides a basic network configuration. You can monitor and control non-critical equipment. However, there is no ability to recover from an architectural fault.

• EtherNet/IP backbone between devices in a star topology

• EtherChannel is optional

• NIC teaming is optional.

• Layer 2 Stratix switches

• Ethernet capable devices

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 15

System Infrastructure

PRP DCS LAN A/B Infrastructure

Ski

Stratix 5400 RedBox VDAN Support

PRP Simplex Connection to Either LAN A/B

LAN LAN LAN LAN

Ski

PRP MCC RedBox Connected to LAN A and LAN B

Ski

LAN LAN

PRP MCC Connected to LAN A/B with DLR Ring

Ring

LAN LAN

MCC

Ski

Stratix 5400 RedBox VDAN Support

Example 4A: PRP Skid and MCC Lineup

16 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Example 4B: DLR Skid and MCC Lineup

DLR Simplex Connection to Either LAN A/B

DLR Member

DLR DCS Integration

DLR Member DLR Member

Skid access switch is DLR member

Ski

DLR Simplex/MCC Connection to DLR Ring Switch

DLR Member

Ski

MCC

DLR Member DLR Member

Ski

Ring (DLR)

MCC

DLR MCC Lineup as part of the DCS DLR Ring

Simplex Connection to Simplex DCS

Ski

Simplex MCC Connection to Simplex DCS

Ski

MCC

System Infrastructure

Example 4C: Simplex Skid and MCC Lineup

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 17

FactoryTalk Network Manager Software

Use FactoryTalk Network Manager to view your network topology and manage switch-level alarms. Monitor the health of network devices and reduce downtime to improve overall efficiency. FactoryTalk Network Manager:

• Discovers network and end devices, including devices across a controller backplane

• Generates an overall topology and a device-centric view of plant floor assets for increased network visibility

• Captures managed switch-level alarms and events for troubleshooting

• Manages configuration backup s and firmware revisions of Stratix managed switches to simplify deployment and maintenance

PlantPAx recommendations include:

• Install FactoryTalk Network Manager on the AppServ-Assert server for consistent monitoring of the network infrastructure.

• You can use an EWS to access the web client for troubleshooting purposes.

• When the network is fully implemented and configured, run the scan of the network.

• The current version of FactoryTalk Network Manager software does not support PRP networks; this will be in a future release.

Table 9 - Requirements

Category Requirement

Hardware Required:

• Quad Core 1.8 Ghz CPU (or greater)

• 8 GB RAM min

• 50 GB free storage space min

Operating system 64-bit versions of these operating systems:

Web browser • Google Chrome browser version 50.0.2661.102 or later

•Windows 10

• Windows 7 Enterprise or Professional with SP2

• Windows Server 2012 R2

•Windows Server 2016

• Mozilla Firefox version 55.0.3 or later

Table 10 - Software and Licenses

Category Cat. No.

FactoryTalk Network Manager software Available as a no charge download from Product Compatibility and Download Center Rockwell Automation software licenses Select a license for each device to manage:

• 9313C-NMMS01T11 (8x5 support)

• 9313C-NMMS01T12 (24x7 support)

Each of these device types requires a license to be accessible by the software:

• Stratix switches

• Controllers

• CIP Sync™ device

•ETAP modules

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 18

Servers and Workstations

The supervisory layer of the PlantPAx system can include several servers and workstations. This section explains the server and workstation system elements to help you define a bill of materials.

PASS Servers

The Process Automation System Server (PASS) is a required system element that hosts essential software components to run the system. The essential software components include the data server, HMI server, and alarm server.

You must determine how many PASS servers are needed for your architecture. If your system requires multiple servers, acquaint yourself with the following descriptions of the data, HMI, and alarm servers.

Table 11 - PASS Server Software Components

Software Components Description

FactoryTalk Directory (FTD) server

FactoryTalk® Activation server

FactoryTalk View HMI server The human machine interface (HMI) server is configured within your FactoryTalk® View SE application. The HMI server

FactoryTalk View Data server The Data server component provides access to information from the process controllers to servers and workstations on

FactoryTalk View Alarm and Event server The Alarm and Event server publishes information from controllers and servers available to all subscribing OWSs. Alarm

Optional

FactoryTalk Batch client software If a Batch Application server is being used on the system, FactoryTalk Batch client components are required to support

(1) In redundant PASS configurations, this component is included on the primary PASS only.

(1)

Secures information from multiple Rockwell Automation software components across multiple computers and allows central administration throughout the PlantPAx system. Application components, such as display and security settings, can be stored in their original environments and made available to the entire PlantPAx system without the need for duplication.

The FactoryTalk Activation server is part of the FactoryTalk® Services Platform. The server is used for FactoryTalk-enabled software products to be activated via files generated by Rockwell Automation over the Internet. This server essentially manages the files that are required to license Rockwell Automation products on the PlantPAx system.

stores HMI project components, such as graphic displays, and serves these components to OWSs upon request. The HMI server can also manage tag databases and log historical data. Multiple HMI servers can exist on the PlantPAx system. Each HMI server must be on a separate PASS.

the PlantPAx system. FactoryTalk View software supports two types of data servers: Rockwell Automation Device servers (FactoryTalk® Linx software) and OPC Data servers. The Data server that is mentioned in PlantPAx documentation generally refers to the Rockwell Automation Device servers. Data servers are configured within your FactoryTalk View SE application. Multiple data servers can exist on the PlantPAx system.

and Event servers are configured within your FactoryTalk View SE application. You can install only one Alarm and Event server on a PASS.

• PlantPAx System Release 5. supports Logix tag-based alarms. These device level, tag-based alarms monitor a tag value to determine the alarm condition. Tag-based alarms are not part of the logic program and do not increase the scan time for a project. The controller caches information, such as timestamps, alarm states, and associated tag values in a 1000 KB buffer. The controller transmits the information to subscribing FactoryTalk Alarm & Event servers.

• For server tag-based alarms a FactoryTalk® Alarms and Events server monitors controllers for alarm conditions through data servers and publishes event information that can be displayed and logged.

replication of batch-related objects on the displays to the OWS.

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Servers and Workstations

FTD Data server HMI server Alarm server

Data server

Alarm server

FTD Data server HMI server Alarm server

HMI server

Data server HMI server Alarm server

FTD

Determine the Number of PASS Servers

The following graphics illustrate how many servers are needed when you are not considering redundancy options.

Table 12 - Non-redundant Server Options

Server Options Description

Option 1 - One PASS System Server This option has all essential software components that are housed in one PASS server. The

components are FTD, Data server, HMI server, and alarm and event server. There are additional system elements, such as batch management, asset management,

FactoryTalk Historian, and FactoryTalk VantagePoint. You can deploy these elements on separate servers or you can deploy elements on the same server as detailed in Option 2.

One HMI server license is required.

Option 2 - One PASS Consolidated Server (small systems) The PASS - C option is for valid small systems with fewer than 2000 I/O points. With this option,

you can locate multiple system elements on the same physical computer.

FTD Data server HMI server Alarm server

Historian VantagePoint AssetCentre SQL

A bootable USB device contains the system elements that are shown in the illustration for Option

One HMI server license is required.

Option 3 - Multiple PASS Servers (additional data capacity) This option contains all software components in one server as shown in Option 1. Option 3 also

adds another server for extra data and alarm capacity without adding another HMI server. If the PASS server is being used as a data server, and additional capacity is needed, you can add

more PASS servers. Use the PSE to determine if more PASS servers are needed. We recommend that you have an HMI server on the PASS if you are segregating the application

into individual operational areas. See Option 4.

One HMI server license is required.

Option 4 - Multiple PASS Servers (logically segregated plant) Place the FTD on its own server to manage applications that exist on multiple client servers. If an

area must be shut down, the other separate areas are not affected because the FTD is on its own server. For example, you can perform maintenance on one area without affecting another operational area of the plant. FTD can be a workstation class machine.

An HMI server license is required for each PASS that contains an HMI server.

The benefits of placing the FactoryTalk Directory on a dedicated server include:

• System Startup: It is best if the FTD is the first component to start and the last to stop. Because most FactoryTalk software products rely on the various services provided by the FTD, the lowest risk scenario is to have it available as these products are initializing.

• Compatibility: While all versions are generally compatible, the FTD is occasionally required to be at the highest version of FTSP installed in the system. This requirement can interfere with another FactoryTalk component if the FTD is co-located with another product.

• Patching/Upgrading: Patching an FTD hosted on a dedicated computer translates to minimum system downtime, as it is not affecting the operation of other FactoryTalk components while rebooting.

• Redundancy: In redundant systems (for example, FactoryTalk View SE, FactoryTalk® Linx, FactoryTalk Alarms and Events), it is best if the FTD remains available during any failover scenarios. While the redundant server pair can function without the presence of the FTD, the lowest risk scenario is keeping it available.

20 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Servers and Workstations

Redundancy can be added to be sure of the availability of critical operations. For PASS servers, you can choose the level of redundancy that you need. When a PASS is made redundant, typically all above elements that are hosted on the PASS are made redundant.

The PASS-C can be made redundant by duplicating the hardware as well. Redundant data servers impact controller memory and communication bandwidth.

Table 13 - PASS Requirements

Category Requirement

Hardware - virtual infrastructure Required:

•4 vCPU

•16 GB vRAM min

•60 GB vHardDisk Recommended CPU and memory allocation:

• High priority Resource pool

Hardware - traditional infrastructure The PASS must be installed on server-class hardware. The following are sample specifications that are based on

PlantPAx system characterization:

• Intel® Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

•16 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

(1)

Table 14 - PASS-C Requirements

Category Requirement

Hardware - virtual infrastructure The PASS-C was tested in a virtual environment using the Stratus zTC Edge 110i with{

• Intel i7-8700T (or greater)

• 2.4GHz GHz CPU min

•32 GB RAM min

• Redundant Ethernet media

Hardware - traditional infrastructure For systems with fewer than 2000 I/O points, the PASS - Consolidated contains HMI, data collection, decision-making,

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

and asset management servers. These combined tools form a basic PlantPAx system in one server, referred to as consolidated.

The PASS must be installed on a server-class computer. The following are sample specifications that are based on PlantPAx system characterization:

• Intel® Xeon E3-1270 v5 (or greater)

•3.60 GHz CPU min

•32 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure it supports redundant media)

The PASS requires that you purchase an HMI server license. If the PASS server is not being used as an HMI server, then no license purchase is required. Make sure to account for process displays, faceplates, and navigation devices in your display count. All displays of the Rockwell Automation Library of Process Objects count against your display count license.

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Servers and Workstations

Whether you deploy a PASS system element in a traditional or virtual architecture, you must purchase the proper activations.

Table 15 - PASS Software and Licenses

Category Cat. No.

Virtual Image Template • 9528-PASSVTENM

USB device contains a virtual image template that has pre-installed applications that are required on the PASS.

Rockwell Automation software licenses Select the following per PASS when the PASS is used as an HMI server:

(1)

• 9528-PASS100ENE (100-display license for PASS)

• 9528-PASS250ENE (250-display license for PASS)

• 9528-PASSUNLENE (unlimited display license for PASS)

• 9528-PASSLICENE (unlimited display license for PASS + 10 OWS licenses)

• 9528-PASS25LICENE (unlimited display license for PASS + 25 OWS licenses) Select the following per PASS when the PASS on the HMI server is a redundant/secondary option:

• 9528-PASS100SECENE (00-display license for secondary PASS)

• 9528-PASS250SECENE (250-display license for secondary PASS)

• 9528-PASSUNLSECENE (unlimited display license for secondary PASS)

• 9528-PASS100SECENM (100-display license for secondary PASS for virtual image template)

(2)

• 9528-PASS250SECENM (250-display license for secondary PASS for virtual image template)

• 9528-PASSUNLSECENM (unlimited display license for secondary PASS for virtual image template)

Disk Image (for PASS-C) Select one copy per project of the following if you use virtualization and virtual image templates:

•9528-PASSCENM USB device contains a bootable image that contains a consolidated PASS that can be installed on a physical machine.The device has pre-installed applications that are required on the PASS.

Rockwell Automation software licenses (for

(4)

PASS-C)

Select one copy per project of the following:

(1)

• 9528-PASS100ENE (100-display license for PASS)

• 9528-PASS250ENE (250-display license for PASS)

• 9528-PASSUNLENE (unlimited display license for PASS)

• 9528-PASSLICENE (unlimited display license for PASS + 10 OWS licenses) Select any of the following:

(3) (4)

• 9528-HSE5KM (5000 FactoryTalk Historian SE tags, 1 VantagePoint server license, and 1 named user are included)

• 9528-ASTSRVRENM (FactoryTalk AssetCentre server)

(1) You can use either the PlantPAx or FactoryTalk View SE software license with the PASS server. (2) The end user is responsible for acquiring the appropriate Microsoft OS license for Server 2016 or Windows 10. (3) You can use either the PlantPAx or FactoryTalk View SE software license with the PASS-C server. (4) If necessary, the end user is responsible for acquiring the Microsoft SQL Server license.

(2)

Engineering Workstation (EWS)

The engineering workstation (EWS) supports system configuration, application development, and maintenance functions. The EWS is the central location for monitoring and maintaining the systems operation. The recommended limit is five EWS per system

Table 16 - EWS Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 8 GB vRAM min

•100 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

Operating system Windows 10 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

22 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

(1)

Servers and Workstations

Table 17 - EWS Traditional Requirements

Category Requirement

Hardware The EWS must be installed on workstation-class hardware. The following are sample specifications that are based on

Operating system Windows 10 operating system, 64 bit Additional third-party software Antivirus software

PlantPAx system characterization:

• Intel Core 2 Duo (or greater)

•2.40 GHz CPU min

• 8 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure that it supports redundant media)

Whether you deploy an EWS system element in a traditional or virtual architecture, you must purchase the proper activations.

Table 18 - EWS Automation System Software and License

Category Cat. No.

Virtual Image Template • 9528-EWSVTENM

USB device contains a virtual image template that has pre-installed all applications that are required on the EWS.

Rockwell Automation software license For each client that is served by the AppServ-EWS:

• 9528-EWSLICENE

(1) This EWS software license is equivalent to a FactoryTalk® View Studio license (9701-VWSTENE), FactoryTalk View SE Client license (9701-VWSCWAENE), and Studio 5000 Logix Designer application

license (9324-RLD700NXENE). You can use the PlantPAx or FactoryTalk and Logix Designer Logix Designer application licenses with the EWS.

(1)

Engineering Workstation Application Servers (AppServ-EWS)

The AppServ-EWS uses Microsoft Remote Desktop Services (RDS) technology to serve multiple instances of the EWS as thin clients from one server. Thin clients can run applications and process data on a remote computer. The recommended limit is five active and connected RDS client connections per AppServ-EWS. The application server can host up to 10 clients, but five only are to be active at one time.

Table 19 - AppServ-EWS Virtual Requirements

Category Requirement

Hardware Required:

•4 vCPU

•16 GB vRAM min

•100 GB vHardDisk Recommended CPU and memory allocation:

Normal priority Resource pool Thin client We recommend a maximum of five active and connected FactoryTalk View SE clients per application server. Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Whether you deploy an AppServ-EWS system element in a traditional or virtual architecture, you must purchase the proper activations.

Table 20 - AppServ-EWS Automation System Software and License

Category Cat. No.

Virtual Image Template • 9528-APPXWSENM

USB device contains a virtual image template that has pre-installed all applications that are required on the EWS.

Rockwell Automation software license IMPORTANT: A Rockwell Automation

license must be purchased for each client that is connected to the AppServ-EWS.

(1) This EWS software license is equivalent to a FactoryTalk View Studio license (9701-VWSTENE), FactoryTalk View SE Client license (9701-VWSCWAENE), and Studio 5000 Logix Designer application

license (9324-RLD700NXENE). You can use the PlantPAx or FactoryTalk and Logix Designer Logix Designer application licenses with the EWS.

For each AppServ-EWS:

• 9528-EWSLICENE

(1)

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Servers and Workstations

Operator Workstations (OWS)

The operator workstation (OWS) provides the graphical view and interface into the process. The OWS supports operator interaction and is not meant to support development or maintenance activities, although these activities are possible if desired.

Table 21 - OWS Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 4 GB vRAM min

•40 GB vHardDisk Recommended CPU and memory allocation:

• High priority Resource pool Operating system Windows 10 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Table 22 - OWS Traditional Requirements

Category Requirement

Hardware The OWS must be installed on workstation-class hardware. The following are sample specifications that are based on

PlantPAx system characterization:

• Intel Core 2 Duo (or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make

Operating system Windows 10 operating system, 64 bit Additional third-party software Antivirus software

(1)

sure that it supports redundant media)

Whether you deploy an OWS system element in a traditional or virtual architecture, you must purchase proper activations.

Table 23 - OWS Automation System Software and License

Category Cat. No.

Virtual image template • 9528-OWSVTENM

USB device contains a virtual image template that has pre-installed all applications that are required on the OWS.

OWS ISO • 9528-OWSISOENM

USB device contains a bootable image to install an operator workstation on a physical machine. The end user is responsible for acquiring the appropriate Microsoft OS license for Windows 10. A Rockwell Automation license is required for software activation.

Rockwell Automation software license For each OWS:

• 9528-OWSLICENE

(1) This PlantPAx software license is equivalent to a FactoryTalk View SE Client license (9701-VWSCWAENE). You can use either a PlantPAx or FactoryTalk View SE software license with

the OWS.

(1)

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Servers and Workstations

Operator Workstation Application Servers (AppServ-OWS)

The AppServ-OWS uses Microsoft Remote Desktop Services (RDS) technology to serve multiple instances of the OWS as thin clients from one server. Thin clients can run applications and process data on a remote computer to minimize the amount of information on a network. The AppServ-OWS is only configured to run FactoryTalk View SE clients and the recommended limit is 10 clients per application server.

Table 24 - AppServ-OWS Virtual Requirements

Category Requirement

Hardware Required:

• 8 vCPU

•16 GB vRAM min

•60 GB vHardDisk Recommended CPU and memory allocation:

• High priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Thin client We recommend a maximum of 10 FactoryTalk View SE clients per application server. Additional third-party software Microsoft Internet Explorer™

Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

(1)

Whether you deploy an AppServ-OWS system element in a traditional or virtual architecture, you must purchase the proper activations

Table 25 - AppServ-OWS Automation System Software and License

Category Cat. No.

Virtual image template • 9528-APPXWSENM

USB device contains a virtual template for the AppServ-OWS.

Rockwell Automation software license Purchase a license for each client that the AppServ-OWS serves:

• 9528-OWSLICENE

(1) This PlantPAx software license is equivalent to a FactoryTalk View SE Client license (9701-VWSCWAENE). You can use either a PlantPAx or FactoryTalk View SE software license with the OWS.

(1)

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Servers and Workstations

ThinManager

Deliver multiple sessions to multiple monitors and customized virtual screens on a single thin client.

Access feeds from USB and IP cameras.

Deliver applications based on what is assigned to the terminal or user.

Deliver content to the right person at the right time and place.

Get mobile access to applications specific to a user’s role.

Manage and deliver virtual desktops while running PCs as a thin client.

Remote Desktop Servers Virtual Resources

ThinManager Server Options

The AppServ-OWS system element virtual-image template is pre-configured with Remote Desktop Services (RDS). The AppServ-OWS includes the ThinManager Server installation file. You can configure the AppServ-OWS as your ThinManager Server and deploy up to 10 OWS sessions to simplify the management of all devices and users.

ThinManager increases your productivity, visualization, mobility, and security from a centralized, and scalable management platform.

Safely and securely deliver your content to any combination of device, user, and location with the following features:

• Boost productivity by reducing the time that is spent in managing computers

• Enhance visualization by delivering your content to where you need it and the way you want it to be shown

• Extend security through encrypted communications, Active Directory, and secure thin clients

• Smart mobility where QR Codes, Bluetooth, Wi-Fi, and GPS make sure that devices receive content in authorized areas

For more information, see Thin Client Management Software

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Servers and Workstations

Independent Workstations (IndWS)

The independent workstation (IndWS) combines the roles of the PASS, EWS, and OWS in one computer. This workstation can be used as a ‘shadow system’ for emergency purposes.

Table 26 - IndWS Traditional Requirements

Category Requirement

Hardware The IndWS must be installed on workstation-class hardware. The following are sample specifications that are based

Operating system Windows 10 operating system, 64 bit Additional third-party software Antivirus software

If you deploy an IndWS system element, you must purchase the proper activations.

on PlantPAx system characterization:

• Intel Multicore processor (4 cores or greater)

•2.40 GHz CPU min

•16 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make

sure that it supports redundant media)

There is no virtual template for the IndWS.

Table 27 - IndWS Automation System Software and Licenses

Category Cat. No.

Rockwell Automation software licenses One per IndWS if being used as EWS:

• 9324-RLD700NXENE (Studio 5000 Logix Designer)

Select one of the following:

• 9701-VWSB100AENE (100 display license with FactoryTalk View SE Station)

• 9701-VWSB250AENE (250 display license with FactoryTalk View SE Station)

• 9701-VWSB000AENE (unlimited display license FactoryTalk View SE Station)

Information Management Application Servers (AppServ-Info)

Information management application servers (AppServ-Info) represent a broad category of servers and software that provides value to the PlantPAx system by offering data management and decision support functionalities. Except where specifically noted, all options that are listed must be installed on their own servers to maximize performance.

Table 28 - Data Management Options

Category Requirement Option

Time series • High-speed, on-machine data collection

• < 2500 tags

• Longer term data storage

• > 2500 tags

Event based Relational database An additional AppServ-Info server can be considered for the storage of transactional

Information Management server is optional because you can use an embedded historian module for the ControlLogix chassis (FactoryTalk Historian ME). If the historian ME module is collecting 2500 points per second, the duration of history that is stored is approximately 14 hours.

• 1756-HIST2G (2 GB) An Information Management server is required with FactoryTalk Historian SE

software.

data. You can select a Microsoft SQL server database to act as the central collection point for event-based data:

• FactoryTalk Alarm and Event data

• FactoryTalk Batch data This database can be installed on an Information Management server or another

server on your system.

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Servers and Workstations

Additional tools to support your information management strategies include:

Table 29 - Decision Support Options

Category Description

FactoryTalk VantagePoint software An Information Management server is required to host this web-based reporting software that brings all data

FactoryTalk Historian ProcessBook software An Information Management server is required to enable ProcessBook content (standard ProcessBook displays, SQC

together into one 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

• Enhanced HMI trends available by using FactoryTalk VantagePoint Trend Active X with FactoryTalk View SE

view, batch view, alarm view). The content is to be hosted and displayed from within FactoryTalk View SE by using the ProcessBook Runtime.

AppServ-Info (Historian)

One of the ways to configure the AppServ-Info is as a historian to collect data. Follow these guidelines if you are adding a Historian server to your PlantPAx system.

Table 30 - AppServ-Info (Historian) Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 4 GB vRAM min

•120 GB vHardDisk Recommended CPU and memory allocation:

• Normal priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Table 31 - AppServ-Info (Historian) Traditional Requirements

(1)

Category Requirement

Hardware The Information Management server must be installed on server-class hardware:

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure that it supports redundant media)

Table 32 - AppServ-Info (Historian) Software

Category Requirement

Virtual image template • 9528-APPHISENM

USB device contains a virtual template for the AppServ-Info (Historian).

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Servers and Workstations

Whether you deploy a Historian system element in a traditional or virtual architecture, you must purchase the proper activations.

Table 33 - FactoryTalk Historian Licenses

Category Cat. No.

FactoryTalk Historian software includes a FactoryTalk VantagePoint software license and one named user client. The number of users is cumulative, and can be a mixed number of named users and concurrent users. If you choose concurrent on the PSE, you must purchase a license for the server based on the number of active CPUs on the server.

Virtual server license

ProcessBook Select for each client that is using ProcessBook:

Excel® Add-in Select one of the following:

(1) If you plan to use redundant Historian for high availability, you must duplicate the number of licenses. Licenses on the backup Historian must mirror the licenses on the primary Historian.

(2) These Historian server licenses are equivalent to a FactoryTalk Historian software a FactoryTalk Historian software license: 9518-HSE250, 9518-HSE500, 9518-HSE1Km 9518-HSE2K5, 9518-HSE5K, and

9518-HSE10K. You can use either the PlantPAx or FactoryTalk Historian software license.

(1)

Select one of the licenses:

• 9528-HSE250 (250 tags for the Historian server)

• 9528-HSE500 (500 tags for the Historian server)

• 9528-HSE1K (1000 tags for the Historian server)

• 9528-HSE2K5 (2500 tags for the Historian server)

• 9528-HSE5K (5000 tags for the Historian server)

• 9528-HSE10K (10,000 tags for the Historian server)

• 9518-HPBENE (FactoryTalk Historian ProcessBook - Single User)

• 9518-HDLENE (FactoryTalk Historian DataLink Excel Add-In - Single User)

• 9518-HDLENFE (FactoryTalk Historian DataLink Excel Add-In - Concurrent User)

(2)

AppServ-Info (VantagePoint)

AppServ-Info can be configured as a decision support tool by using FactoryTalk VantagePoint software.

Table 34 - AppServ-Info (VantagePoint) Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 4 GB vRAM min

•60 GB vHardDisk Recommended CPU and memory allocation:

• Normal priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Table 35 - AppServ-Info (VantagePoint) Traditional Requirements

Category Requirement

Hardware The Information Management server must be installed on server-class hardware:

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1)

Table 36 - AppServ-Info (VantagePoint) Software

Category Requirement

Virtual image template • 9528-APPVTPENM

USB device contains a virtual template for the AppServ-Info (VantagePoint).

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Servers and Workstations

Whether you deploy a VantagePoint system element in a traditional or virtual architecture, you must purchase the proper activations.

Note: FactoryTalk VantagePoint software licenses consist of user clients. The number of users is cumulative, and can be a mixed number of named users and concurrent users. If you choose concurrent on the PSE, you must purchase a license for the server based on the number of active CPUs on the server.

Table 37 - FactoryTalk VantagePoint Licenses

Category Cat. No.

Virtual server license • 9528-VPSERVERENE Virtual server named user licenses Select one or more of the following for FactoryTalk VantagePoint Client named users:

• 9528-VPNL01ENE (1 named user)

• 9528-VPNL03ENE (3 named users)

• 9528-VPNL05ENE (5 named users)

• 9528-VPNL010ENE (10 named users)

Virtual server named user licenses Select one or more of the following for FactoryTalk VantagePoint Client concurrent users:

• 9528-VPCL01ENE (1 concurrent user)

• 9528-VPCL03ENE (3 concurrent users)

• 9528-VPCL05ENE (5 concurrent users)

• 9528-VPCL010ENE (10 concurrent users)

Virtual server concurrent user licenses If VantagePoint is being used for concurrent users, select one for each CPU of the hosting server:

Virtual server data connector licenses Select the following:

• 9528-VPCPPENE

• 9528-VPHSCENE

AppServ-Info (SQL)

Another way to configure AppServ-Info is as a Microsoft SQL Server relational database. Software such as FactoryTalk AssetCentre, FactoryTalk VantagePoint, and FactoryTalk Batch use a SQL Server database to store and access process data. The FactoryTalk Alarm and Event server uses a SQL Server database to store information.

The process library includes standard reports that support basic and advanced alarm and event reports along with per process object reporting.

Table 38 - AppServ-Info (SQL) Virtual Requirements

Category Requirement

Hardware Required:

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

•2 vCPU

• 4 GB vRAM min

•120 GB vHardDisk Recommended CPU and memory allocation:

• Normal priority Resource pool

Table 39 - AppServ-Info (SQL) Traditional Requirements

Category Requirement

(1)

Hardware

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Microsoft SQL Server

(1) A Microsoft Excel software license is required.

The Information Management server must be installed on server-class hardware:

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make

Antivirus software

(1)

sure that it supports redundant media)

30 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Servers and Workstations

Microsoft SQL Server is licensed in one of two ways: Server + CAL or Per Core. ‘CAL’ is an abbreviation for client access license. Server+CAL licensing is recommended for fewer clients. Every additional client requires a CAL license. Per Core licensing provides unlimited number of CALs.

Whether you deploy a Microsoft SQL Server system element in a traditional or virtual architecture, you must purchase the proper licensing. The end user is responsible for acquiring the appropriate Microsoft SQL Server licensing.

Category Requirement

Virtual image template • 9528-APPSQLENM

USB device contains a virtual template for the AppServ-Info (SQL).

Asset Management Servers (AppServ-Asset)

An asset management server (AppServ-Asset) is an extension to the PlantPAx system that adds maintenance and plant operations to the system with FactoryTalk AssetCentre software. This server provides controller data backup for disaster recovery, diagnostics, and real-time monitoring. The server also audits assets and monitors network health to improve overall resource availability.

The asset management server provides centralized system management for Rockwell Automation and third-party field assets.

Table 40 - AppServ-Asset Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 4 GB vRAM min

•60 GB vHardDisk Recommended CPU and memory allocation:

• Normal priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

(1)

Table 41 - AppServ-Asset Traditional Requirements

Category Requirement

Hardware The Asset Management server must be installed on server-class hardware:

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

Table 42 - AppServ-Asset Software

Category Requirement

Virtual image template • 9528-APPASMENM

USB device contains a virtual template for the AppServ-Asset.

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Servers and Workstations

Whether you deploy an AppServ-Asset system element in a traditional or virtual architecture, you must purchase the proper activations.

Table 43 - AppServ-Asset Licenses

Category Cat. No.

Virtual server licenses • 9528-ASTSRVRENE Virtual server asset licenses Select one or more of the following so that the sum of licenses is equal to or greater than the number of assets that is to be

managed by the Asset Management server:

• 9528-ASTCAP0005E (5 additional assets)

• 9528-ASTCAP0025E (25 additional assets)

• 9528-ASTCAP0100E (100 additional assets)

• 9528-ASTCAP0500E (500 additional assets)

Virtual server disaster recovery licenses If disaster recovery is to be used, select all following:

• 9528-ASTDRROKENE (Disaster recovery for Rockwell Automation)

• 9528-ASTDRRCENE (Disaster recovery for remote computers)

(1) The Virtual server licenses are equivalent to FactoryTalk AssetCentre licenses that start with 9515. You can use a virtual server or a FactoryTalk AssetCentre software license with an Asset

Management system element.

(1)

Batch Management Servers (AppServ-Batch)

PlantPAx systems support scalable options for batch management that are based on ISA88 standards:

Feature Logix Batch & Sequence

Manager

Deployment Logix controller code Firmware-based controller feature Server-based application (AppServ-Batch) Supported controllers ControlLogix 5580

CompactLogix 5380 ControlLogix 5570

CompactLogix 5370 Units Single unit recipes Single unit recipes Multiple unit recipes Phase construction PhaseManager™ programs PhaseManager programs PhaseManager programs Phase interface Phase and bit logic Pull-down menu Pull-down menu Max recipes/steps/phases 32 Limited by memory or resources Limited by memory or resources Max input/report parameters 4 No max No max Parameter expressions No Yes Yes Parameter data types BOOL

REAL

Procedural structure Sequential

Concurrent

Recipe design Tabular HMI configured SFC like SFC like Recipe editing Runtime via HMI Import only at runtime Runtime editing via Recipe Editor HMI integration Faceplates 3 Active X 4 Active X

Batch reporting Queue controller services Event client and archive services Event client and archive services FactoryTalk Batch integration No Yes Na Dynamic unit binding No No Yes Unit arbitration No No Yes

SequenceManager™ FactoryTalk® Batch

ControlLogix 5570 CompactLogix 5370

BOOL INT, INT, DINT REAL

Sequential Concurrent Divergent Recurrent

ControlLogix 5580 CompactLogix 5380 ControlLogix 5570 CompactLogix 5370

BOOL SINT, INT, DINT REAL

Sequential Concurrent Divergent Recurrent

API

32 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Servers and Workstations

The batch management server (AppServ-Batch) offers equipment-independent recipe management, batch-independent equipment control, and regulatory compliance.

Table 44 - AppServ-Batch Virtual Requirements

Category Requirement

Hardware Required:

•2 vCPU

• 4 GB vRAM min

•60 GB vHardDisk Recommended CPU and memory allocation:

• Normal priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Table 45 - AppServ-Batch Traditional Requirements

Category Requirement

Hardware The Batch Management server must be installed on server-class hardware:

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1)

Table 46 - AppServ-Batch Software

Category Requirement

Virtual image template • 9528-APPBATENM

USB device contains a virtual template for the AppServ-Asset.

Whether you deploy an AppServ-Batch in a traditional or virtual architecture, you must purchase the proper activations.

Table 47 - AppServ-Batch Licenses

Category Cat. No.

Batch unit software licenses Purchase multiple licenses to obtain the desired number of batch units.

Batch backup software licenses If a back-up server is enabled on the PlantPAx System Estimator, an additional server is added to the BOM with an equal number

eProcedure® software licenses eProcedure is included with Batch licenses that are listed above. These catalog numbers are to order software separately.

• 9358-FTB01ENE (1 unit)

• 9358-FTB03ENE (3 units)

• 9358-FTB10ENE (10 units)

• 9358-FTB30ENE (30 units)

• 9358-FTB60ENE (60 units)

of back-up server unit licenses.

• 9358-FTBKY01ENE (1 unit)

• 9358-FTBKY03ENE (3 units)

• 9358-FTBKY10ENE (10 units)

• 9358-FTBKY30ENE (30 units)

• 9358-FTBKY60ENE (60 units)

• 9358-EP03ENE (3 units)

• 9358-EP10ENE (10 units)

• 9358-EP30ENE (30 units)

• 9358-EP60ENE (60 units)

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 33

Servers and Workstations

Table 47 - AppServ-Batch Licenses

eProcedure backup software licenses eProcedure is included with Batch licenses that are listed above. These catalog numbers are to order software separately.

• 9358-EPBKY03ENE (3 units)

• 9358-EPBKY10ENE (10 units)

• 9358-EPBKY30ENE (30 units)

• 9358-EPBKY60ENE (60 units)

Batch high availability options depend on the hardware and software options in the system:

• For the application server in a system where a bump in the process cannot be tolerated, FactoryTalk Batch software helps support a real-time, uninterrupted high availability option. This option leverages Stratus servers or VMware virtualization.

• Standard FactoryTalk Batch software supports a warm back-up option that allows a Batch server to start up and rebuild the active batches from the Event Journals and Logs and places them on the batch list in a held state.

• A redundant ControlLogix system with PhaseManager software provides protection so that the control platform continues to execute during a hardware failure.

Domain Controllers

PlantPAx uses a domain controller to store user account information, authenticate users, and enforce security policies. Follow these guidelines for the domain controller:

• A domain controller is required if there are 10 or more workstations or servers.

• A domain controller is a separate computers. Do not load any application software on a domain controller. Load all system application software on the other computers, such as the PASS, application server, OWS, and EWS.

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

Table 48 - Domain Virtual Requirements

Category Requirement

Hardware Required:

•1 vCPU

• 4 GB vRAM min

•40 GB vHardDisk Recommended CPU and memory allocation:

• Low-priority Resource pool Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

(1) All numbers and figures are referenced for initial sizing only. If needed, adjust these values for system performance.

Table 49 - Domain Traditional Requirements

(1)

Category Requirement

Hardware The Information Management server must be installed on server-class hardware:

Operating system Windows Server 2016 operating system, 64 bit Additional third-party software Antivirus software

• Intel Xeon Multicore processor (4 cores or greater)

•2.40 GHz CPU min

• 4 GB RAM min

• Ethernet card that supports redundant media if NIC-teaming is used (If you plan to use a motherboard-NIC make sure it supports redundant media)

Table 50 - Domain Software

Category Requirement

Virtual image template • 9528-PADCVTENM

USB device contains a virtual template for the AppServ-Asset.

34 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Controllers, Field Networks, and I/O

The optimal number of controllers for the PlantPAx system depends on the size of your application, physical layout of your plant, and the design of your process. Consider segregating non-related process equipment into separate controllers so that maintenance activities in one area do not impact the operation of another area.

PlantPAx system release 5.0 adds process controllers to the Logix 5000™ family of controllers. The process controller is an extension of the Logix 5000 controller family that focuses on plantwide process control. The process controller is preconfigured with a default process tasking model and dedicated PlantPAx process instructions optimized for process applications to improve design and deployment efforts.

Regardless of which type of controller that you use, controllers are capacity limited. This capacity can be roughly estimated based on I/O count, but is also greatly impacted by the design of your application. These limitations can include the amount of automation code that is required, the amount of information being read by supervisory applications, and the number of alarms configured in your system.

Table 51 - Process and Standard Controller Hardware

Category Cat. No.

Process controllers • ControlLogix 1756-L81EP, 1756-L83EP, 1756-L85EP

• CompactLogix 5069-L32OERP, 5069-L34OERP

Standard controllers • ControlLogix 1756-L71, 1756-L72, 1756-L73, 1756-L74, 1756-L75, 1756-L81E, 1756-L82E, 1756-L83E, 1756-L84E,

Standard Ethernet interfaces (ControlLogix) • For direct DLR connection: 1756-EN2TR

1756-L85E

• CompactLogix 1769-L24ER-Q, 1769-L33ER, 1769-L36ERM

• For direct PRP connection: 1756-EN2TP

• For secure connections: 1756-EN2TSC

• Otherwise: 1756-EN2T, 1756-EN2F

Simplex Controllers

Non-redundant controllers are referred to as simplex controllers.

Table 52 - Simplex - Process Controllers

(1)

Category

User memory 3 MB 10 MB 40 MB PID loop control strategies @ 100 ms max 185 570 PID loop control strategies @ 250 ms max 625 1425 PID loop control strategies @ 500 ms max 2000 PID loop control strategies @ 1000 ms max Tags/sec delivered to data server max 50,000 Logix alarms max 7500

(1) These values are recommended maximum limits. It’s possible that achieving all of these values in one controller is not doable. For more detailed sizing, you can use the PSE.

1756-L81EP 1756-L83EP 1756-L85EP

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 35

Controllers, Field Networks, and I/O

Table 53 - Simplex - Standard Controllers

(1)

Category

1756-L71 1756-L72 1756-L73 1756-L74 1756-L75 1756-L81E 1756-L82E 1756-L83E 1756-L84E 1756-L85E

User memory 2 MB 4 MB 8 MB 16 MB 32 MB 3 MB 5 MB 10 MB 20 MB 40 MB PID loop control strategies

75 85 235 425 500

@ 100 ms max PID loop control strategies

175 215 910 1250

@ 250 ms max PID loop control strategies

380 430 1875 2000

@ 500 ms max PID loop control strategies

800 860

@ 1000 ms max Tags/sec delivered to data

10,000 20,000 50,000

server max

(1) These values are recommended maximum limits. It’s possible that achieving all of these values in one controller is not doable. For more detailed sizing, you can use the PSE.

Redundant Controllers

ControlLogix controllers support redundancy on EtherNet/IP networks. For a PlantPAx system, you need these components:

Table 54 - Redundant Process and Standard Controller Hardware

Category Cat. No.

Process redundant controllers ControlLogix 1756-L81EP, 1756-L83EP, 1756-L85EP Standard redundant controllers

• ControlLogix 1756-L73, 1756-L74, 1756-L75

• ControlLogix 1756-L81E, 1756-L82E, 1756-L83E, 1756-L84E, 1756-L85E

Redundancy module 1756-RM2

(2)

Standard Ethernet interfaces • For direct DLR connection: 1756-EN2TR

• For direct PRP connection: 1756-EN2TP

• Otherwise: 1756-EN2T, 1756-EN2F

(1) ControlLogix 1756-L71 and 1756-L72 controllers are not recommended for PlantPAx systems due to memory constraints. (2) The PlantPAx system recommendation is to use only one redundant controller in a chassis with a 1756-RM2 redundancy module.

Table 55 - Redundant - Process Controllers

(1)

Category

1756-L81EP 1756-L83EP 1756-L85EP

User memory 3 MB 10 MB 40 MB PID loop control strategies @ 100 ms max 125 PID loop control strategies @ 250 ms max 190 325 325 PID loop control strategies @ 500 ms max 625 650 PID loop control strategies @ 1000 ms max 1300 Tags/sec delivered to data server max 50,000 Logix alarms max 7500

(1) These values are recommended maximum limits. It’s possible that achieving all of these values in one controller is not doable. For more detailed sizing, you can use the PSE.

(1)

36 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Table 56 - Redundant - Standard Controllers

(1)

Category

User memory 8 MB 16 MB 32 MB 3 MB 5 MB 10 MB 20 MB 40 MB PID loop control strategies @ 100 ms max 40 65 PID loop control strategies @ 250 ms max 100 155 PID loop control strategies @ 500 ms max 150 195 240 315 PID loop control strategies @ 1000 ms max 315 400 430 625 Tags/sec delivered to data server max 10,000 20,000 50,000

(1) These values are recommended maximum limits. It’s possible that achieving all of these values in one controller is not doable. For more detailed sizing, you can use the PSE.

1756-L73 1756-L74 1756-L75 1756-L81E 1756-L82E 1756-L83E 1756-L84E 1756-L85E

Controllers for Skid-based Equipment

The CompactLogix controller platform offers a solution for skid-based equipment to be part of the overall PlantPAx system if the application requires the following:

• Control of multiple loops for temperature, pressure, flow, or level

• Operating as a subsystem with sequencing and automation

• Controlled as part of the overall process, accepting reference inputs and delivering process variables to a supervisory controller

Table 57 - Skid-based Controllers

(1)

Category

User memory 0.75 MB 2 MB 3 MB 2 MB 4 MB PID Loop Control Strategies

@ 100 ms max PID Loop Control Strategies

@ 250 ms max PID Loop Control Strategies

@ 500 ms max PID Loop Control Strategies

@ 1000 ms max Tags/s ec delivered to 

data server max Logix alarms max — 7500

(1) These values are recommended maximum limits. It is possible that some controllers might not achieve all of these values. For more detailed sizing, use the PSE.

CompactLogix 1769-L24ER-Q

12 35 50 125 250

3000 50,000

CompactLogix 1769-L33ER

CompactLogix 1769-L36ERM

CompactLogix 5069-L32OERP (Process Controller)

CompactLogix 5069-L34OERP

(Process Controller)

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 37

Controllers, Field Networks, and I/O

I/O Products

Field networks and I/O components connect process instrumentation and field devices to the PlantPAx system for real-time data acquisition and control. The PlantPAx system supports several families of I/O.

Table 58 - I/O Communication Interfaces

Category Family Communication Interface Cat. No.

Chassis-based I/O modules 1756 ControlLogix I/O • 1756-EN2T, 1756-EN2TP, 1756-EN2TR, 1756-EN3TR,

1756-EN2F, 1756-EN2TXT, 1756-EN2TSC

For more information, see the ControlLogix System Selection Guide, publication 1756-SG001

5069 Compact 5000™ I/O • 5069-AENTR dual-port EtherNet/IP adapter

• 5069-AENTRK dual-port EtherNet/IP adapter, conformal coated

• 5069-AEN2TR dual-port EtherNet/IP adapter with display diagnostics, integrated USB port, and SD card

For more information, see Compact 5000 I/O Modules and EtherNet/IP Adapters Specifications Technical Data, publication 5069-TD001

1769 Compact I/O™ • 1769-AENTR

For more information, see the CompactLogix Communication Modules Specifications Technical Data, publication 1769-TD007.

Distributed I/O, low-channel density 1734 POINT I/O™ • 1734-AENT, 1734-AENTR EtherNet/IP adapters

• 1734-ADN, 1734-ADNX, 1734-PDN DeviceNet® adapters

For more information, see the POINT I/O Modules Selection Guide, publication 1734-SG001.

Distributed I/O, high-channel density 5094 FLEX 5000™ I/O • 5094-AENTR, 5094-AENTRXT

• 5094-AEN2TR, 5094-AEN2TRXT

• 5094-AENSFPR, 5094-AENSFPRXT

• 5094-AEN2SFPR, 5094-AEN2SFPRXT

For more information, FLEX 5000 Modules Specifications Technical Data, see publication 5094-TD001

1794 FLEX™ I/O • 1794-AENT, 1794-AENTR, 1794-AENTRXT EtherNet/IP adapters

• 1794-ADN, 1794-ADNK DeviceNet adapters

• For more information, see the FLEX I/O, FLEX I/O-XT, and FLEX Ex Selection Guide, publication 1794-SG002

Distributed I/O, no cabinet enclosure 1738 ArmorPOINT® I/O • 1738-AENT, 1738-AENTR EtherNet/IP adapters

• 1738-ADN12, 1738-ADN18, 1738-ADN18P, 1738-ADNX DeviceNet adapters

For more information, see the ArmorPoint I/O Selection Guide, publication 1738-SG001.

Condition monitoring module 1444 Dynamix™ I/O • Built-in Ethernet connectivity with 1444-DYN04-01RA module

For more information, see the Dynamix -1444 Series Monitoring System User Manual, publication 1444-UM001

Redundant I/O 1715 Redundant I/O • 1715-AENTR Redundant EtherNet/IP adapter

For more information, see the 1715 Redundant I/O System Specifications Technical Data, publication 1715-TD001

Intrinsically Safe I/O 1719 Class 1, Div 2 I/O • 1719-AENTR Intrinsically safe EtherNet/IP adapter

For more information, see the 1719 Ex I/O Technical Data, publication 1719-TD001

38 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Table 59 - Online Addition of Module and Connection Types

Controllers, Field Networks, and I/O

Module Type and Connection Method

In Local Chassis Remote via an

EtherNet/IP

Remote via a ControlNet® Network Configure Hold

Network

OfflineRuntime OfflineRuntime Offline Runtime Offline only

ScheduledUnscheduledScheduledUnschedul

Digital - direct Yes Yes Yes Yes Yes Yes — Yes

Digital - rack-optimized — — Yes Yes Yes — Yes —

Analog - direct Yes Yes Yes Yes Yes Yes — Yes Yes Generic third-party - direct Yes Yes Yes Yes Yes Yes — Yes — 1715 Redundant I/O — — Yes Yes — — — — —

1718/1719 I/O — — Yes Yes — — — —

1756-ENx - no connection Yes Yes Yes Yes — — — — — 1756-ENx - rack-optimized — — Yes Yes — — — — — Generic EtherNet/IP

third-party - direct 1788-EN2FFR or

1788-EN2PAR 1788-CN2FFR or 

1788-CN2PAR

—— YesYes — — — — —

—— —— No Yes — — —

1794 FLEX I/O — — Yes — Yes Yes — —

1734 POINT I/O — — Yes — Yes Yes — — Yes 1734 POINT Guard I/O™ Yes — Yes — — — — — —

5069 Compact 5000 I/O Yes — Yes

5069 Compact 5000 I/O Safety Modules

Yes — Yes — — — — — —

Yes

(1)

—— —— Yes

5094 FLEX 5000 — — Yes Yes — — — — Yes 5094 FLEX 5000 I/O Safety

Modules

(1) Only supported if adding an entire rack of Compact 5000 I/O modules.

—— Yes— — — — — Yes

Last Output State

Yes - 1756 I/O digital output modules

Yes – both analog and digital modules

Yes - Analog output modules only

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 39

Controllers, Field Networks, and I/O

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.

The EtherNet/IP network technology is owned and managed by ODVA, a global association of member companies that advance open, interoperable information, and communication technologies in industrial automation.

Field instruments that support a direct connection to EtherNet/IP networks include the following:

• Endress+Hauser, Promass 83 and compact Promass 100 Coriolis flowmeters for liquid and gas flows

• Endress+Hauser, Promag 53 electromagnetic flowmeter for conductive liquids

• Endress+Hauser, Liquiline CM444 Multiparameter transmitter for monitoring and controlling processes

• Endress+Hauser, Proline Promag 100 Electromagnetic flowmeter for conductive liquids

• Endress+Hauser, Proline Promag L 400 Electromagnetic flowmeter for conductive liquids

EtherNet/IP Network

Stratix 5700

Promass 100

Process Network Devices

PlantPAx leverages smart instrumentation to provide the right information to the right personnel at the right time. In a PlantPAx system, controllers are connected to field devices via field device components and communicate seamlessly through EtherNet/IP, DeviceNet, FOUNDATION Fieldbus, and PROFIBUS PA networks or by using HART protocol.

EtherNet/IP Devices

Table 60 - EtherNet/IP Interface

Category Cat. No. Description

ControlLogix EtherNet/IP interface 1756-EN2T, 1756-EN2TP, 1756-EN2TR,

1756-EN3TR, 1756-EN4T, 1756-EN4TR, 1756-EN2F

ControlLogix time synchronization 1756-TIME Provides time synchronization by acting as a gateway between different time

ControlLogix EtherNet/IP bridge

synchronization methods and standards

40 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Controllers, Field Networks, and I/O

HART Devices

HART is an open communication protocol that is designed to connect analog devices to the controller and system.

The PlantPAx system interfaces with HART devices both directly and via remote I/O modules. The HART protocol creates one termination point to gather analog process variables and the additional HART digital data.

Highly-integrated HART provides a PlantPAx data type in the process controller for use with FLEX 5000 modules:

• Configuration of devices within the I/O Configuration tree (no Add-On Instruction needed)

• Device diagnostics automatically propagate to the controller project

Table 61 - HART Interface

Category Cat. No. Description

Chassis-based I/O modules 1756-IF8H, 1756-IF16H, 1756-OF8H Allen-Bradley® analog I/O with the following:

• 8-channel HART analog input module

• 16-channel HART analog input module

• 8-channel HART analog output module

1756-IF8IH, 1756-IF16IH, 1756-OF8IH Allen-Bradley isolated analog I/O with the following:

• 8-channel isolated HART analog input module

• 16-channel isolated HART analog input module

• 8-channel isolated HART analog output module

Distributed I/O, high-channel density 1794-IF8IH, 1794-OF8IH Allen-Bradley FLEX isolated analog I/O modules with the following:

1794-IF8IHNFXT Allen-Bradley FLEX I/O module with the following:

5094-IF8IH, 5094-IF8IHXT 5094-OF8IH, 5094-OF8IHXT

Distributed I/O, low-channel density 1734sc-IE2CH, 1734sc-IE4CH Spectrum Controls, analog input module for the POINT I/O system

1734sc-OE2CIH Spectrum Controls, isolated analog input module for the POINT I/O system

1769sc-IF4IH, 1769sc-OF4IH Spectrum Controls, isolated analog Compact I/O modules with HART:

• 8-channel isolated HART analog input module

• 8-channel isolated HART analog output module

• Extended temperature, noise filtering 8-channel isolated HART analog input module

Allen-Bradley HART I/O with the following:

• 8-channel isolated HART

• 8-channel isolated HART extreme temperature

• 2-channel HART analog input module

• 4-channel HART analog output module

• 2-channel isolated HART analog output module

• 4-channel isolated HART analog input module

• 4-channel isolated HART analog output module

See the Encompass website for Spectrum Controls for product offerings.

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 41

Controllers, Field Networks, and I/O

1788-FBJB6

Junction Box

EtherNet/IP

1788-EN2FFR Linking Device

FF Field Devices

EtherNet/IP Network

EtherNet/IP Device Level Ring

1788-EN2FFR Linking Devices

FF Field Devices

EtherNet/IP Network

1788-FBJB4R Junction Boxes

H1 Network

Table 61 - HART Interface

Category Cat. No. Description

Distributed I/O, intrinsically safe 1718-CF4H, 1718-IF4HB

1719-CF4H, 1719-IF4HB

1715 Redundant I/O Modules 1715-IF16, 1715-OF8I Allen-Bradley redundant I/O with the following:

Wireless HART

•SWA70

•SWG70

•RSG4

•WHA-ADP

•WHA-BLT

•WHA-GW

Allen-Bradley EX I/O chassis-based design for Zone 2 or Class I, Div 2., via EtherNet/IP:

• 4-channel configurable HART analog module

• 4-channel HART analog input module

• 4-channel HART analog input-wide module

• 16-channel HART analog input module

• 8-channel isolated HART analog output module

Endress+Hauser wireless HART:

• WirelessHART adapter

• WirelessHART fieldgate

• Data manager

Pepperl+Fuchs wireless HART:

• WirelessHART adapter

• WirelessHART bullet adapter

• Wireless HART gateway

FOUNDATION Fieldbus Devices

The FOUNDATION Fieldbus network is a protocol that is designed for robust, distributed process application control. Devices that are connected by a FOUNDATION Fieldbus network can be used for sophisticated process control with seamless data distribution from the H1 device-level network.

PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNet/IP linking devices as shown in the examples. Other configurations are available for simplex and redundant topologies.

Table 62 - FOUNDATION Fieldbus Interface

Category Cat. No. Description

EtherNet/IP interface 1788-EN2FFR Bridge from an Ether net network to an H1 network. Supports redundant media and

42 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

DLR-capable Ethernet network. Linking devices have built-in termination.

Controllers, Field Networks, and I/O

PROFIBUS PA Devices

EtherNet/IP Device Level Ring

1788-EN2PAR Linking Device

EtherNet/IP

PROFIBUS PA Devices

1788-FBJB6

Junction Box

EtherNet/IP Network

1788-EN2PAR Linking Devices

1788-FBJB4R Junction Boxes

Table 62 - FOUNDATION Fieldbus Interface

Category Cat. No. Description

FOUNDATION Fieldbus network components

Power conditioning Included in the 1788-EN2FFR and 1788-CN2FFR linking devices. 1788-FBJB4R Intelligent junction box supports redundancy, includes four drop ports and four

trunk ports. 1788-FBJB6 Intelligent junction box with six drop ports and two trunk ports. Additional components Pepperl+Fuchs, FOUNDATION Fieldbus components, such as valve couplers, surge

protectors, and distributors.

See the Encompass website for Pepperl+Fuchs product offerings. Segment protection Helps protect against device or line faults with short- and open-circuit protection.

Pepperl+Fuchs, intrinsic safety components, such as isolated barrier systems,

hazardous area enclosures, and equipment.

See the Encompass website for Pepperl+Fuchs product offerings.

PROFIBUS PA Devices

The PROFIBUS PA network connects automation systems and process control systems with field devices such as flow, level, pressure, and temperature transmitters.

PlantPAx systems communicate with PROFIBUS PA fieldbus devices through EtherNet/IP linking devices. Other configurations are available for simplex and redundant topologies.

Table 63 - PROFIBUS PA Interface

Category Cat. No. Description

PROFIBUS interface 1788-EN2PAR EtherNet/IP to PROFIBUS PA linking device. Supports redundant

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 43

PROFIBUS PA media and DLT-capable Ethernet network. Linking devices

have built-in terminators.

Controllers, Field Networks, and I/O

RUNSDOKFORCE

Logix5575

EtherNet/IP™

EtherNet/IP Network

PowerFlex 525 PowerFlex 753 PowerFlex 755

Table 63 - PROFIBUS PA Interface

Category Cat. No. Description

PROFIBUS network components Power conditioning Included in the 1788-EN2PAR and 1788-CN2PAR linking devices.

1788-FBJB4R Intelligent junction box supports redundancy, includes four drop ports and four

trunk ports. 1788-FBJB6 Intelligent junction box with six drop ports and two trunk ports. Additional components Pepperl+Fuchs

(1)

, PROFIBUS components, such as valve couplers, surge

protectors, and distributors.

See the Encompass website for Pepperl+Fuchs product offerings. Segment protection Helps protect against device or line faults with short- and open-circuit protection.

Pepperl+Fuchs, intrinsic safety components, such as isolated barrier systems,

hazardous area enclosures, and equipment.

See the Encompass website for Pepperl+Fuchs product offerings.

(1) For more information on Encompass third-party products, see http://www.rockwellautomation.com/encompass.

Motor Control Devices

Rockwell Automation offers a broad range of motor control solutions to complement various application requirements. The portfolio of motor control devices includes simplified programming and configuration along with safety features to help protect personnel and assets that help to reduce downtime.

Low Voltage Drives

PowerFlex® Low Voltage AC drives provide scalable motor control solutions and are designed to deliver more powerful performance and flexibility for process applications. As part of a PlantPAx system, PowerFlex drives offer seamless integration into your process control system for simplified development, use, and maintenance.

Table 64 - PowerFlex Drives and Communication Modules

Drive Cat. No.

25B- PowerFlex 525 AC drive with an embedded EtherNet/IP

20F- PowerFlex 753 AC drive • 20-750-BNETIP 20G- PowerFlex 755 drive

20G- PowerFlex 755TL/755TR • 20-750-DNET

(1) For a complete list of catalog numbers, see the PowerFlex Low Voltage AC Drives Selection Guide, publication PFLEX-SG002.

(1)

Description Available Communication Modules

Cat. No. Description

• 25-COMM-E2P

port and an embedded Safe Torque Off (STO).

• 25-COMM-D

• 20-750-DNET

• 20-750-ENETR

• 20-750-PBUS

• 20-COMM-D

• 20-COMM-E

• 20-COMM-P

• 20-750-ENETR

• 20-750-PBUS

(1)

• Dual-port EtherNet/IP, supports DLR functionality

• DeviceNet

• BACnet/IP option modules

• DeviceNet option module

• Dual-port EtherNet/IP option module

• PROFIBUS DPV1 option module

• DeviceNet communication adapter

• EtherNet/IP communication adapter

• PROFIBUS DP communication adapter

• DeviceNet option module

• Dual-port EtherNet/IP option module

• PROFIBUS DPV1 option module

44 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Medium Voltage Drives and Relays

RUNSDOKFORCE

Logix5575

EtherNet/IP™

EtherNet/IP Network

EWS

PowerFlex 7000 PowerFlex 6000

857 Relay 865 Relay

EtherNet/IP Network

SMC Flex SMC-50

PowerFlex medium voltage AC drives and relays provide scalable motor control solutions and electrical protection. Standalone drives control speed, torque, direction, starting, and stopping of standard asynchronous or synchronous AC motors. As part of a PlantPAx system, PowerFlex drives incorporate leading-edge technology, embedded communications, and significant commonality across multiple platforms, networks, operator interface programming and hardware. The benefits of this exceptional level of integration between the drives and Logix controllers provides distinctive time-saving features for the PowerFlex 6000 and 7000 drives.

Table 65 - Medium Voltage Drives and Relays

Drive Cat. No.

PF-6000 PowerFlex 6000 • Anybus-AB7007

PF-7000 PowerFlex 7000 • 20-750-ENETR

Bulletin 857 857 relay Embedded with product; depends on

Bulletin 865 865 relay Embedded with product; depends on

(1) For a complete list of catalog numbers, see the PowerFlex Medium Voltage AC Drives Selection Guide, publication PFLEX-SG003.

(1)

Description Available Communication Modules

Cat. No. Description

• USB-RS-232

• 20-COMM-E

application requirement

Controllers, Field Networks, and I/O

(1)

• Third-party, EtherNet/IP gateway

• Configuration adapter (order code 019570)

• Dual-port EtherNet/IP option module

• EtherNet/IP communication adapter

See the Product Configuration Assistant

or contact

your Rockwell Automation representative See the Product Configuration Assistant

or contact

your Rockwell Automation representative

Soft Starters

EtherNet/IP™

SMC™ Soft Starters are designed to help minimize cost by reducing overall system power requirements and wear and tear on equipment. Our soft starters can be easily integrated into your process control system to offer higher productivity and shorter downtimes.

Table 66 - SMC Soft Starters and Communication Modules

(1)

Cat. No.

150-F SMC™ Flex Smart Motor Controllers • 20-COMM-D

150-S SMC™-50 Solid-state Smart Motor Controllers • 20-COMM-D

(1) For additional product information, see the Smart Motor Controllers – SMC™-3, SMC™ Flex, and SMC-50 Soft Starters Family Brochure, publication 150-BR144.

Description Available Communication Modules

Cat. No. Description

• 20-COMM-E

• 20-COMM-ER

• 20-COMM-E

• 20-COMM-ER

Logix5575

RUNSDOKFORCE

(1)

• DeviceNet communication adapter

• EtherNet/IP communication adapter

• Dual-port EtherNet/IP communication adapter

• DeviceNet communication adapter

• EtherNet/IP communication adapter

• Dual-port EtherNet/IP communication adapter

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 45

Controllers, Field Networks, and I/O

RUNSDOKFORCE

Logix5575

EtherNet/IP™

EtherNet/IP Network

E-1 Plus

E-300

E-3 Plus

EWS Control Room HMI Controller Maintenance PC

EtherNet/IP Network

CENTERLINE 2500 MCC

PowerFlex Drives CENTERLINE 2100 MCC Medium Voltage Equipment

Across-the-line Starters

Our light industrial IEC starters are environmentally friendly, versatile, and flexible. Our heavy-duty NEMA starters are renowned for a more-rugged construction, more dependable performance, and longer electrical life. In addition, this portfolio offers Electronic Overload Relays that provide integration between the starters and Logix controllers. The diagnostic capabilities of the overload relays help maximize uptime for motor control in an automation system.

Table 67 - Electronic Overload Relays and Communication Modules

(1)

Cat. No.

193/592-EE E1 Plus™ Electronic Overload Relays • 193-ETN

193/592-EC E3 Plus™ Electronic Overload Relays with embedded

193/592-E300 E300™ Electronic Overload Relays 193-ECM-ETR EtherNet/IP communication module

(1) For additional product information, see the Motor Protection Solutions Brochure, publication 193-BR029.

Description Available Communication Modules

Cat. No. Description

•193-EDN 193-DNENCAT EtherNet/IP communication auxiliary DeviceNet

DeviceNet

193-DNENCATR EtherNet/IP communication auxiliary DeviceNet

(1)

• EtherNet/IP module

• DeviceNet module

to EtherNet/IP linking device, single port

to EtherNet/IP linking device, dual-port

Motor Control Centers

As an alternative to wiring each device individually, Rockwell Automation offers low-voltage motor control centers (MCC). The MCCs feature a rugged, high-performance packaging solution for all your motor control needs that integrate control and power in one centralized location.

CENTERLINE® MCCs are available with safety options that help reduce exposure to electrical hazards and arc flash mitigation and containment.

Table 68 - Low Voltage Motor Control Centers

Category

CENTERLINE 2100 MCC 2100 • Designed to meet UL and NEMA standards

CENTERLINE 2500 MCC 2500 • Designed to meet IEC standards

(1) For more information, see Low Voltage Motor Control Centers.

(1)

Cat. No. Description

• Allen-Bradley motor control devices: starters, soft-starters, and drives

• Available with SecureConnect™ units

• ArcShield™ arc-resistant enclosures available

• EtherNet/IP and DeviceNet networking

• IntelliCENTER® software

• Allen-Bradley motor control devices: starters, soft-starters, and drives

• ArcShield™ arc-resistant enclosures available

• EtherNet/IP and DeviceNet networking

• IntelliCENTER software

46 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Analytics

Basic Analytics Advanced Analytics

Analytics is the discovery, interpretation, and communication of meaningful patterns in data. Analytics relies on the application of statistics, computer programming, and operations research to quantify performance.

Analytics provides methods to measure our performance and then provide feedback for continuous improvement. Analytics drive business value, regardless of the industry, by helping to:

• bring a product to market faster

• lower the total cost of ownership because of more effective maintenance

• improve asset utilization by maximizing the throughput

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 47

Analytics

Device Level Options

Allen-Bradley products have device-level diagnostics built in, such as fault and alarm codes for use in fault routines. Other products provides predictive and prescriptive analytics at the device-level of the architecture.

Device-level analytics provide:

• Streaming analysis

• Runtime deployment

• Device data generation

Products that provide device-level analytics include:

Option Description

FactoryTalk® Analytics™ for Devices An embedded analytics software that lets you implement device

level, descriptive and diagnostics analytics to improve maintenance and engineering reliability. Automated device health diagnostics provides data to an information platform with or without cloud connectivity

PlantPAx specific content:

• Advanced Process Controller action card

• E+H device support

• Robust HART diagnostic information.

FactoryTalk® Analytics™ LogixAI® An embedded analytics software that enables controls engineers

to apply models to make predictions in ControlLogix applications. Automated modeling capabilities that enable predictive capabilities in the controller.

Type: Descriptive, Diagnostic

Environment: Appliance on EtherNet/IP network

Available via the subscription portal

Requirements:

• 6200PC-FTA4DT11M FactoryTalk Analytics for Devices appliance

Type: Diagnostic, Predictive

Environment: ControlLogix chassis

Available via the subscription portal

PlantPAx® MPC Model Predictive Control embedded in ControlLogix systems

• Multi-variable in and multi-variable out

• Predictive control

• Reduction in variability

APC Function Blocks You can use APC function blocks in place of PID instructions for

loops with long dead-times and interacting loops. The APC function blocks are licensed, run on the EWS, and require the Studio 5000 Logix Designer application.

• Internal model control (IMC) to control one process variable

• Coordinated control (CC) to control one process variable with up to three control variables

• Modular mulitvariable control (MMC) to control two process variables with up to three control variables

Requirements:

• 1756M-FTALGXAIT11M FactoryTalk Analytics LogixAI appliance

Type: Predictive, Prescriptive

Environment: ControlLogix chassis

Requirements:

• 1756-PPMPC or 9529-PPMPCENM module

Type: Predictive, Prescriptive

Environment: Logix 5000 function blocks

Requirements:

• 9324-RLDAPCENE for first controller

• 9324-RLDAPCCLENE for subsequent controllers

48 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

System Level Options

System-level analytics provide:

• Data reduction, management, transformation, and harmonization

• Model training and deployment

• Pattern extractions

FactoryTalk products that add system-level analytics include:

Option Description

FactoryTalk® Analytics™ Augmented Modeler Provides an interactive machine learning environment for plant

Pavilion8® Provides closed-loop, prescriptive analytics to maximize process

FactoryTalk® Analytics Edge ML (also applicable at enterprise level)

FactoryTalk® Analytics™ DataFlowML (also applicable at enterprise level)

FactoryTalk® Analytics™ DataView (also applicable at enterprise level)

engineers and application domain experts to build analytic applications.

System-level analytics provide:

• Data reduction, management, transformation, and harmonization

• Model training and deployment

• Pattern extractions

Discovers machine, unit, or line anomalies sooner with alerts that indicate unusual states.

performance in quality, throughput and efficiency.

• Model-based advanced, dynamic control drives stable performance

• Integrated MPC, calculation, and soft sensor visualization and performance reporting

A machine learning application that provides expert-driven data analytics within the plant, where low latency is a requirement.

• Helps make decisions as close as possible to the data

• Reduce loads on controllers by off-loading data preprocessing

• Reduces deployment time costs

• Out-of-box connectivity reduces design time

Helps identify data trends and presents insights proactively. Use for expert-driven analytics, but where latency is not a requirement. Use to operationalize models.

• Corrects anomalies before downtime or quality events occur

• Connects multiple types of complex machine learning models with the data from your intelligent assets

• Offers data exploration, cleansing, preparation capabilities to empower data scientists

Transform and manipulate data (batch/stream)

• Aggregate, join, slice, thin, and operate on data streams

• Ingest high volume/high velocity to low volume/low velocity use cases

• Reuse models across the enterprise

A visualization tool that lets you access and transform data through storyboards. Gain a business understanding of data to pinpoint opportunities for improvement.

• Reduces time to value by reducing the dependence on data architects and data scientists

• Enables self-service analytics

• Minimizes the need for expensive infrastructure that is associated with traditional warehousing

Type: Predictive

Environment: Server based

Part of the FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics Augmented Modeler software – Includes FactoryTalk® Analytics™ Data Explorer as

a data preparation tool

Type: Predictive, Prescriptive

Environment: Server based

Requirements:

• Pavilion8 software

Type: Predictive

Environment: Server based

Part of the FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics Edge ML base bundle

• FactoryTalk Analytics Platform base bundle

Type: Predictive, Prescriptive

Environment: Server based

Part of FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics DataFlowML base bundle

• FactoryTalk Analytics Platform base bundle

Type: Descriptive, Diagnostic

Environment: Server based

Part of FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics DataView base bundle

• FactoryTalk Analytics Platform base bundle

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 49

Analytics

Enterprise-Level Options

Enterprise-level analytics provide:

• Data visualization

• Data mining

• Enterprise resource planning

• Model training

• Model operationalization

• Pattern extraction

FactoryTalk products that add enterprise-level analytics include:

Option Description

FactoryTalk Analytics Edge ML (also applicable at system level)

FactoryTalk Analytics DataFlowML (also applicable at system level)

FactoryTalk Analytics DataView (also applicable at system level)

A machine learning application that provides expert-driven data analytics within the plant, where low latency is a requirement.

• Helps make decisions as close as possible to the data

• Reduce loads on controllers by off-loading data preprocessing

• Reduces deployment time costs

• Out-of-box connectivity reduces design time

Helps identify data trends and presents insights proactively. Use for expert-driven analytics, but where latency is not a requirement. Use to operationalize models.

• Corrects anomalies before downtime or quality events occur

• Connects multiple types of complex machine learning models with the data from your intelligent assets

• Offers data exploration, cleansing, preparation capabilities to empower data scientists

Transform and manipulate data (batch/stream)

• Aggregate, join, slice, thin, and operate on data streams

• Ingest high volume/high velocity to low volume/low velocity use cases

• Reuse models across the enterprise

A visualization tool that lets you access and transform data through storyboards. Gain a business understanding of data to pinpoint opportunities for improvement.

• Reduces time to value by reducing the dependence on data architects and data scientists

• Enables self service analytics

• Minimizes the need for expensive infrastructure that is associated with traditional warehousing

Type: Predictive

Environment: Server based

Part of the FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics Edge ML base bundle or

• FactoryTalk Analytics Platform base bundle

Type: Predictive, Prescriptive

Environment: Server based

Part of FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics DataFlowML base bundle or

• FactoryTalk Analytics Platform base bundle

Type: Descriptive, Diagnostic

Environment: Server based

Part of FactoryTalk Analytics; available via the subscription portal

Requirements:

• FactoryTalk Analytics DataView base bundle or

• FactoryTalk Analytics Platform base bundle

50 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Option Description

Vuforia® Augmented Reality An industrial augmented reality platform that can improve

workforce efficiency and customer satisfaction with real-time, step-by-step work instructions and data.

• Work instructions become handsfree and are delivered in real time where assembly or field service take place.

• Tribal knowledge of experienced workers is captured and shared with new workers and service technicians.

• Remote expertise can be delivered to workers no matter where they are in the world.

PlantPAx specific support:

• Process strategy experience templates provide users with faceplate-like features within an AR experience. The templates enable users to build additional functionality around the PlantPAx information.

ThingWorx® Industrial IoT platform An integrated, secure solution to minimize risk, reduce IT burden,

and maximize value from the software investment. ThingWorx industrial connectivity provides data access for client applications such as MES and SCADA and IoT and Big Data analytics software. It leverages OPC and IT-centric communication protocols to provide one source of industrial data. Supported protocols include proprietary protocols (including GE NIO, SuiteLink/FastDDE, and Splunk), IT protocols (including MQTT, REST, ODBC, and SNMP), and flow measurement export to common oil and gas industry formats. ThingWorx industrial connectivity provides one solution to collect, aggregate, and securely access industrial operations data. Connect, manage, monitor, and control diverse automation devices and software applications through one intuitive user interface.

Analytics

Type: Descriptive, Diagnostic

Environment: Cloud-based

Part of the FactoryTalk® InnovationSuite Bulletin 95057C; available via the subscription portal

Requirements:

•Vuforia Engine software

• Vuforia Studio software

• Vuforia Chalk software

• Vuforia Expert Capture software

Type: Descriptive, Diagnostic, Predictive, Prescriptive

Environment: Cloud-based

Part of the FactoryTalk Innovation Suite Bulletin 95057C; available via the subscription portal

Requirements:

• ThingWorx platform software

-Asset Advisor

- Operator Advisor

- Production Advisor

- ControlAdvisor

• ThingWorx Industrial Connectivity software

PlantPAx specific support:

• Process strategy Thing templates replicate structure and functionality within ThingWorx, which enable users to create an analysis of the objects with Live and Historical Data

• ThingWorx mashup templates provide the ability to investigate alarms by area, priority, and other critical alarming criteria. Advanced alarm analysis includes fleeting, chattering, and stale alarm insights. Similar dashboard functionality is also provided for SQL server reporting services.

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 51

Process Safety Systems

Tru s t e d

AADvance

Contr olLogi x

A process automation solution often includes the requirement for an integrated safety system as part of the overall Safety Instrumented System (SIS) requirements for a process facility. The SIS logic solver is a separate but integrated technology that can use common or diverse technology to meet the safety integrity needs for any process application.

The SIS logic solver requirements can include fault tolerance, fail-safe, or a mix of architecture and Safety Integrity Level (SIL) requirements. Fault tolerance means that plant operation is maintained if a fault occurs, while fail-safe means that the SIS initiates a shutdown upon detecting a fault.

Table 69 - Typical SIL and Architecture System Requirements

Process Safety Platform Safety Application Architecture Typical SIL Range Demand

Emergency shutdown/SIS Fault Tolerant Up to SIL 3 Low/High Fire and gas SIL 2 Low High integrity pressure system SIL 3 Chemical processing Up to SIL 3 High

Low/High

Refining

Process Safety Platform Safety Application Architecture Typical SIL Range Demand

Burner management (continuous process)

(1)

Subsea Power generators

Fault Tolerant Up to SIL 3 High

SIL 2 Low

Process Safety Platform Safety Application Architecture Typical SIL Range Demand

Burner management (power and utilities) Fail-safe SIL 2 High Turbomachinery Life sciences Low Mining Fault Tolerant Power equipment Specialty chemical Low/High High Availability control systems

(1) The AADvance solution is available in a Eurocard format, qualified for Subsea production applications under ISO13628-6. (2) ControlLogix controllers are limited to a demand rate not to exceed 10 demands per year. While this is a high demand rate, this solution possibly could not be suitable for high-demand applications.

(2)

Safe, reliable systems safeguard people, property, the environment, and company or corporate reputations. Third-party certification for applying technologies in applications up to a specific SIL level significantly reduces complexity when complying with national and international process safety standards worldwide.

Process safety technology selection is based on functional and target SIL requirements, which are defined in the projects Safety Requirements Specification (SRS). For example, if the SRS requirement is for the Safety Instrumented Function to fail safely upon a fault, you can select a fail-safe only technology. If however, some level of fault tolerance is defined for your process safety system, you can select a fault tolerant technology.

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 52

Process Safety Systems

There are different levels of fault tolerance available. For example:

• 1oo2d refers to a voting and degradation architecture where diagnostics are used to determine the validity of two values or states. When both values are ‘healthy’, then either one out of the two (1oo2) available is used in the outcome of the safety instrumented function (SIF). When one of the two values or states is determined to be ‘invalid’, then that value or state is no longer considered when determining the outcome of the SIF. (The voting degrades to 1oo1, one out of the remaining good one). This dramatically reduces the spurious trip rate of a basic 1oo2 architecture, while maintaining safety performance.

• 2oo3 refers to a voting and degradation architecture where comparison diagnostics are used to determine the outcome of the SIF. Two ‘out of’ the three (2oo3) available values or states are required to determine the outcome of a SIF. This architecture, often referred to as Triple Modular Redundancy (TMR), lets a failed value or state be ignored when resolving the SIF.

In addition to the comparison diagnostics, active diagnostics are also used to validate states and values that are used in the outcome of the SIF.

ControlLogix SIL 2 Systems

ControlLogix supports process safety applications up to SIL 2 that require fault tolerance and redundancy. ControlLogix supports 1oo2d fault tolerance with the 1715 I/O system. However, ControlLogix redundancy does not use a voting mechanism, rather it acts as a hot standby. The components of the 1715 I/O system comprise a pair of partnered Ethernet adapters that communicate to ControlLogix controllers via an EtherNet/IP network, and digital and analog I/O modules that are configurable in simplex and duplex modes.

The ControlLogix controller complies with the requirements of the relevant standards (SIL 2 according to IEC 61508) and can be used in low demand applications up to SIL 2 according to IEC 61508). The instructions of the associated Safety Reference Manual and User Manuals are to be considered.

ControlLogix SIL 2 systems use the same programming software and data interfaces as used for process control on the PlantPAx system. The hardware that is used for process safety must be dedicated for process safety applications. Specific hardware, firmware revisions, and software versions are required to meet SIL certifications.

AADvance and Trusted SIL 2, SIL 3, and TMR Systems

Diverse SIS logic solvers use different hardware and software platforms for process safety applications than that used for process control on the PlantPAx system. This approach is used to minimize common cause faults from influencing the overall safety integrity. Triple redundancy minimizes the possibility of any single component failure to cause a spurious or spurious trip. Diverse process safety integrates with the basic process control on the PlantPAx system by using CIP™ connectivity including profile support in the Studio 5000 Logix Designer application (AADvance) or via OPC connectivity (AADvance or Trusted®).

Both the Trusted and AADvance systems share a common EtherNet/IP network within a PlantPAx system. In addition, AADvance and Trusted support redundant Ethernet networks, while the AADvance system supports the CIP producer and consumer communication protocol.

Table 70 - Diverse SIL 2 and SIL 3 Products

Category Description

AADvance system • Configurable for SIL 2 and SIL 3

• Scalable redundancy for fault tolerance

• Simplex, duplex, or triplex configuration

Trusted system Trusted technology uses 3-2-0 (3-2-2-0 optionally) fault-tolerant control to help eliminate spurious trips. Triple

modular redundancy (TMR) uses majority voting to identify a source of failure. Available with OPC or CIP integration.

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 53

Table 71 - Additional Resources

Resource Description

AADvance Controller Solutions Handbook, publication ICSTT-RM447 Explains the features, performance, and functionality of the AADvance controller and

systems. It sets out some guidelines on how to specify a system to meet your application requirements.

AADvance Controller System Build Manual, publication ICSTT-RM448

AADvance Controller Configuration Guide, publication ICSTT-RM405

AADvance Controller Safety Manual, publication ICSTT-RM446 Provides mandatory guidance on how to apply AADvance to meet various industry

AADvance Controller Troubleshooting and Repair Manual, publication ICSTT-RM406

Provides experienced panel builders with information on how to assemble a system, switch on and validate the operation of a controller.

Defines how to configure an AADvance controller by using the AADvance Workbench to meet your Safety Instrument Function (SIF) application requirements.

standards and makes recommendations to apply AADvance in SIS applications safely. Provides plant maintenance personnel with information on how to trace and repair a

fault in an AADvance system and perform routine maintenance tasks.

SIL-rated Instruments

SIL-rated instruments are typically required for process safety loops. Rockwell Automation provides premier integration between ControlLogix systems and Endress+Hauser SIL-rated instruments. For more details, see the Endress+Hauser website at https://www.endress.com.

PowerFlex SIL 2 and SIL 3 Systems

PowerFlex AC drives offer SIL ratings up to and including SIL 3. Specifically, the PowerFlex 525 AC drive offers Safe Torque Off (STO) as a standard embedded feature with a safety rating of PLd/SIL2 Cat. 3. The PowerFlex 753 and 755 AC drives are available with optional STO functionality with a safety rating of PLe/SIL3 Cat. 3. In addition, the PowerFlex 753 and 755 offer a Safe Speed Monitor option for applications that can benefit from access to a safety zone while there is limited motion. The Safe Speed Monitor option has a rating of PLe/SIL3 Cat. 4.

PowerFlex STO functionality is designed to help safely remove power from the gate firing circuits of the output power devices (IGBTs). This functionality helps prevent the output power devices from switching in the pattern necessary to generate AC power to the motor. PowerFlex AC drives can be used in combination with other safety devices to satisfy the requirements of IEC 61508, IEC 61800-5-2 SIL 3, ISO 13849-1 PLe, and Category 3 for STO.

For more information, see the PowerFlex Low Voltage AC Drives Selection Guide, publication PFLEX-SG002

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 54

Process Safety Systems

OptiSIS Safety Integrated Systems

The OptiSIS® safety system uses an AADvance safety logic solver for a process safety solution that is ready to install and configure with no programming required. OptiSIS lets you configure safety functions by using an intuitive Cause and Effect interface from the HMI display.

OptiSIS includes options for:

• Fail-safe or fault tolerant architectures

• Indoor or outdoor environments

• Floor and wall mount

• 50 or 100 I/O count

OptiSIS is a great solution for small process safety applications. In addition, if you have an existing process safety system (for example, an older relay or legacy system) that can no longer be maintained, OptiSIS can provide a cost-effective and short delivery replacement.

For more information, see the OptiSIS Packaged Solution Profile, publication 1711-PP006

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 55

Process Safety Systems

Notes:

56 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021

Notes:

PlantPAx Distributed Control System Selection Guide

Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 57

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Publication PROCES-SG001N-EN-P - March 2021

Allen-Bradley PlantPAx User manual

Specifications and Main Features

Frequently Asked Questions

User Manual

What’s Inside

Additional Resources

Select a PlantPAx System

Scalable Architectures

PlantPAx System Estimator

Software Release Information

PlantPAx System ID

PlantPAx PASS Large Bundle (Perpetual)

PlantPAx PASS Medium Bundle (Perpetual)

PlantPAx PASS Small Bundle

Recommended Products

System Infrastructure

Traditional Infrastructure

Virtual Infrastructure

Template Distribution

VMware Component Requirements

VMware Sizing

Reference Network Topologies

Example 1: Redundant PRP Topology

Example 2: Resilient DLR Topology

Example 3: Simplex - Star Topology

Example 4A: PRP Skid and MCC Lineup

Example 4B: DLR Skid and MCC Lineup

Example 4C: Simplex Skid and MCC Lineup

FactoryTalk Network Manager Software

Servers and Workstations

PASS Servers

Determine the Number of PASS Servers

Engineering Workstation (EWS)

Engineering Workstation Application Servers (AppServ-EWS)

Operator Workstations (OWS)

Operator Workstation Application Servers (AppServ-OWS)

ThinManager Server Options

Independent Workstations (IndWS)

Information Management Application Servers (AppServ-Info)

AppServ-Info (Historian)

AppServ-Info (VantagePoint)

AppServ-Info (SQL)

Asset Management Servers (AppServ-Asset)

Batch Management Servers (AppServ-Batch)

Domain Controllers

Controllers, Field Networks, and I/O

Simplex Controllers

Redundant Controllers

Controllers for Skid-based Equipment

I/O Products

Process Network Devices

EtherNet/IP Devices

HART Devices

FOUNDATION Fieldbus Devices

PROFIBUS PA Devices

Motor Control Devices

Analytics

Device Level Options

System Level Options

Enterprise-Level Options

Process Safety Systems

ControlLogix SIL 2 Systems

AADvance and Trusted SIL 2, SIL 3, and TMR Systems

SIL-rated Instruments

PowerFlex SIL 2 and SIL 3 Systems

OptiSIS Safety Integrated Systems