Allen-Bradley PlantPAx User manual
PlantPAx Distributed Control
System
Selection Guide
Selection Guide
Original Instructions
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.
2 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021
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.
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 3
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.
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 4
Scalable Architectures
S
c
a
l
a
b
l
e
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.
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 5
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™
6 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021
.
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.
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 7
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
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 8
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.
Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021 9
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.
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
12 Rockwell Automation Publication PROCES-SG001N-EN-P - March 2021
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
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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
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System Infrastructure
PRP DCS LAN A/B Infrastructure
DC
Ski
Stratix 5400 RedBox
VDAN Support
PRP Simplex Connection to Either LAN A/B
LAN LAN LAN LAN
DC
Ski
PRP MCC RedBox Connected to LAN A and LAN B
DC
Ski
LAN LAN
PRP MCC Connected to LAN A/B with DLR Ring
Ring
LAN LAN
DC
MCC
MCC
Ski
Stratix 5400 RedBox
VDAN Support
Stratix 5400 RedBox
VDAN Support
Example 4A: PRP Skid and MCC Lineup
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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
DC
Ski
DC
Ski
DLR Simplex/MCC Connection to DLR Ring Switch
DLR Member
DC
Ski
MCC
DLR Member DLR Member
DC
Ski
Ring (DLR)
MCC
DLR MCC Lineup as part of the DCS DLR Ring
Simplex Connection to Simplex DCS
Ski
DC
Simplex MCC Connection to Simplex DCS
DC
Ski
MCC
System Infrastructure
Example 4C: Simplex Skid and MCC Lineup
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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
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