Rockwell Automation PlantPAx Reference Manual

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Page 1

Reference Manual

Original Instructions

PlantPAx Distributed Control System

System Release 4.6

IMPORTANT This manual applies to PlantPAx System Release 4.5/4.6.

For PlantPAx System Release 5.0, see PROCES-UM100.

Page 2

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Page 3

Preface

Purpose of the Reference Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

System Architecture Overview Architecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Critical System Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

System Procurement Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 2 System Element Recommendations

PlantPAx Software Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Process Automation System Server (PASS) . . . . . . . . . . . . . . . . . . . . . . 18

PASS Server Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Configure the FactoryTalk Directory . . . . . . . . . . . . . . . . . . . . . . . 20

Engineering Workstation (EWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Engineering Workstation Application Server (AppServ-EWS) . . . . 21

Operator Workstation (OWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operator Workstation Application Server (AppServ-OWS) . . . . . . 22

Independent Workstation (IndWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

AppServ-Info (Historian). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AppServ-Info (VantagePoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AppServ-Info (SQL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Asset Management Server (AppServ-Asset). . . . . . . . . . . . . . . . . . . . . . 25

Batch Management Server (AppServ-Batch). . . . . . . . . . . . . . . . . . . . . 26

Domain Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Controller Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Simplex Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Skid-based Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Determining I/O Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Sizing Control Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Table of Contents

Chapter 3

System Application Recommendations

Alarm System Recommendations

Infrastructure Recommendations

Controller Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Task Configuration and CPU Utilization . . . . . . . . . . . . . . . . . . . 38

Estimate Controller CPU Utilization . . . . . . . . . . . . . . . . . . . . . . . 40

Use of Program Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Tag and Memory Allocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Controller-to-Controller Communication . . . . . . . . . . . . . . . . . . 47

Controller I/O Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Using Add-On Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FactoryTalk View Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Rockwell Automation Library of Process Objects. . . . . . . . . . . . . . . . 53

Additional Application Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 4

FactoryTalk Alarm and Event Software . . . . . . . . . . . . . . . . . . . . . 55

Using the Library of Process Objects for Alarms. . . . . . . . . . . . . . 59

Alarm State Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Monitoring Your Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Chapter 5

Physical Access Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Infrastructure Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Traditional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Virtual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Virtual PlantPAx Configuration Recommendations . . . . . . . . . . . . . 67

Servers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Virtual Networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Resource Pool Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Operating System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Domains and Workgroups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Domain Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Windows Workgroup Recommendations . . . . . . . . . . . . . . . . . . . 73

Server and Workstation Time Synchronization . . . . . . . . . . . . . . 73

Operating System Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Network Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Ethernet Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

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Chapter 6

Table of Contents

Field Device Integration Recommendations

Batch Management and Control Recommendations

Device Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

FactoryTalk AssetCentre for Enterprise Solution . . . . . . . . . . . . 78

EtherNet/IP Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

EtherNet/IP I/O Communication Options . . . . . . . . . . . . . . . . . 79

ControlNet Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

ControlNet I/O Communication Options . . . . . . . . . . . . . . . . . . 80

DeviceNet Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

DeviceNet Communication Options. . . . . . . . . . . . . . . . . . . . . . . . 81

HART Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

HART Communication Options. . . . . . . . . . . . . . . . . . . . . . . . . . . 82

FOUNDATION Fieldbus Recommendations . . . . . . . . . . . . . . . . . . 83

FOUNDATION Fieldbus Communication Options . . . . . . . . 83

PROFIBUS PA Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

PROFIBUS PA Communication Options. . . . . . . . . . . . . . . . . . . 85

Motor Control Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 7

FactoryTalk Batch Critical System Attributes . . . . . . . . . . . . . . . . . . . 90

Batch Guidelines for Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Using a Redundant System with a FactoryTalk Batch Server . . . . . . 91

Information Management Recommendations

Chapter 8

FactoryTalk Historian Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Tips and Best Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Architectural Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

FactoryTalk VantagePoint Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Tips and Best Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 5

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Table of Contents

Chapter 9

Maintenance Recommendations

PlantPAx System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Host Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Virtual Image Disaster Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Hypervisor Management Applications . . . . . . . . . . . . . . . . . . . . . . 97

Application Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Controller Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

FactoryTalk Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

PASS Servers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Network Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Data Back up and Restore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Historian Configuration and Data . . . . . . . . . . . . . . . . . . . . . . . . . 100

Batch Configuration and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

AssetCentre Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

SQL Server Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Backup Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Retention Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

System Storage Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Security Audit Logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Microsoft Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Use Antivirus Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Software Patches and Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . 106

Use Proactive Industrial Security Advisory Index. . . . . . . . . . . . 106

Verify Software Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Compare Latest Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . 107

Considerations for Software and Firmware Upgrades. . . . . . . . 107

Rockwell Automation Services and Support . . . . . . . . . . . . . . . . . . . . 108

Appendix A

Verify and Monitor Your System

Additional Monitoring Resources. . . . . . . . . . . . . . . . . . . . . . . . . . 109

Health

Appendix B

System Software Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Glossary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

Page 7

The PlantPAx® system provides a modern approach to distributed control. The

Dene and

Procure

Install Prep

Develop Operate

• Selection Guide

PROCES-SG001

• Virtualization User Manual

9528-UM001

• Infrastructure User Manual

PROCES-UM001

• Reference Manual

PROCES-RM001

• Application User Manual

PROCES-UM003

• Reference Manual

PROCES-RM001

• Library of Process Objects

PROCES-RM002 PROCES-RM013 PROCES-RM014

• Verify and Troubleshoot User Manual

PROCES-UM004

• Reference Manual

PROCES-RM001

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. Figure 1 the highlighted section) that are available to help design and implement your system requirements.

Figure 1 - PlantPAx System Implementation and Documentation Strategy

Preface

shows the documents (this manual in

• Define and Procure - Helps you understand the elements of the PlantPAx system to make sure that you buy the proper components.

•Install - Provides direction on how to install the PlantPAx system.

•Prep - Provides guidance on how to get started and learn the best practices

to follow before you develop your application.

•Develop - Describes the actions and libraries necessary to construct your application that resides on the PlantPAx system.

•Operate – Provides guidance on how to verify and maintain your systems for efficient operation of your plant.

Purpose of the Reference Manual

The PlantPAx Reference Manual builds on the Selection Guide, which specifies system sizing guidelines and catalog numbers for procurement. This manual elaborates on the system sizing and application rules that you need to follow to configure a PlantPAx system.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 7

Page 8

Preface

We strongly recommend that you use the PlantPAx virtual image templates and Rockwell Automation® Library of Process Objects for best system performance and functionality. If you are not able to use the templates or the library, you still must follow the guidelines and rules from the Selection Guide and this Reference Manual. These guide posts make sure that you achieve PlantPAx system performance.

The PlantPAx system utilizes a set of Critical System Attributes (CSAs) as performance metrics. Your system performance can meet the CSA metrics if you follow the sizing guidelines and application rules that are defined in these documents and the PlantPAx System Estimator (PSE).

Summary of Changes

This manual contains new and updated information as indicated in the following table.

Top ic Pag e

120 OWS clients available in distributed architecture 14

Updates characterized software releases 17

Adds hard disk size for virtual system elements 19, 20, 21, 22,

Updates software components of system elements 111

Additional Resources

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

Table 1 - System Core Resources

Resource Description

PlantPAx Distributed Control System Selection Guide, publication PROCES-SG001

PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001

PlantPAx Distributed Control System Application Configuration User Manual, publication PROCES-UM003

PlantPAx Distributed Control System Verification and Troubleshooting User Manual, publication PROCES-UM004

Rockwell Automation Library of Process Objects, publication PROCES-RM002

Rockwell Automation Library of Logix Diagnostic Objects, publication PROCES-RM003

Rockwell Automation Library of Steam Table Instructions, publication PROCES-RM004

Rockwell Automation Library of Process Objects: Logic Instructions Reference Manual, publication PROCES-RM013

Rockwell Automation Library of Process Objects: Display Elements Reference Manual,

publication PROCES-RM014

Provides basic definitions of system elements and sizing guidelines for procuring a PlantPAx system.

Provides screen facsimiles and step-by-step procedures to configure infrastructure components for your system requirements.

Provides the steps necessary to start development of your PlantPAx Distributed Control System.

Provides checklist worksheets to verify and document that your system design aligns with PlantPAx system recommendations.

Provides information on how to use the Rockwell Automation Library of Process Objects.

Provides Add-On Instructions for monitoring and diagnostic information of Logix controllers.

Provides Add-On Instructions for calculating temperature and pressure steam tables.

Provides controller codes and tags for Rockwell Automation Library objects. The objects are grouped by family and attached as Microsoft Excel® files to the manual PDF file.

Provides common display elements for the Rockwell Automation Library. For improved accessibility, the elements are combined into one manual.

24, 25, 26, 27

8 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

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Table 1 - System Core Resources

Resource Description

PlantPAx Hardware Specifications and Certifications, publication PROCES-SR027

PlantPAx Sequencer Object Reference Manual, publication PROCES-RM006

FactoryTalk® View SE Edition User Manual, publication VIEWSE-UM006

FactoryTalk View SE Installation Guide, publication VIEWSE-IN003

FactoryTalk Alarms and Events System Configuration Guide, publication FTAE-RM001

ControlLogix® System User Manual, publication 1756-UM001

ControlLogix Enhanced Redundancy System User Manual, publication 1756-UM535

Logix5000™ Controllers Design Considerations Reference Manual, publication 1756-RM094

Logix5000 Controllers Common Procedures Programming Manual, Publication 1756-PM001

Logix5000 Controllers General Instructions Reference Manual, publication 1756-RM003

Logix5000 Controllers Advanced Process Control and Drives Instructions Reference Manual, publication 1756-RM006

Logix 5000 Controllers Execution Time and Memory Use Reference Manual, publication 1756-RM087

PlantPAx Logix Batch and Sequence Manager Reference Manual, publication PROCES-RM007

Provides information on PlantPAx system hardware specifications and certifications.

Provides a flexible controller-based step sequencing solution that reduces engineering time by automating common operator procedures.

Provides details on how to use this software package for developing HMI applications that can involve multiple users and servers, which are distributed over a network.

Contains procedures for installing FactoryTalk View SE software.

Provides details on how to install, configure, and use FactoryTalk Alarms and Events services as part of a FactoryTalk-enabled automation system.

Explains how to use traditional and extreme environment ControlLogix controllers.

Provides information on the installation and configuration for an enhanced redundancy controller system for greater availability.

Details how to design and optimize Logix5000 controller applications.

Provides links to a collection of programming ma nuals that describe how you can use procedures that are common to all Logix5000 controller projects.

Provides programming controller applications by using relay ladder instructions.

Provides details on process control and drives instructions.

Provides a complete list of instruction execution time and memory usage information for Logix5000 controllers in your Studio 5000 Logix Designer® programming software.

Explains a controller-based batch and sequencing solution that leverages the Logix Control Platform and FactoryTalk View software for integrated control and visualization.

Preface

Table 2 - Infrastructure Resources

Resource Description

PlantPAx Virtualization User Manual, publication 9528-UM001

EtherNet/IP Network Configuration, publication ENET-UM001

Ethernet Design Considerations Reference Manual, publication ENET-RM002

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

Troubleshoot EtherNet/IP Networks, publication ENET-AT003

1756 ControlLogix Communication Modules Specifications Technical Data, publication 1756-TD003

Application Note: Segmentation Methods within the Cell/Area Zone, publication ENET-AT004

Stratix® Managed Switches User Manual, publication 1783-UM007

Stratix Ethernet Device Specifications Technical Data, publication 1783-TD001

Stratix/Infrastructure Product Family Quick Reference Drawing, publication IASIMP-QR029

Describes how to use the PlantPAx virtua l image templates for configuring virtual machines.

Explains Logix5000 tools that are used in EtherNet/IP topologies and network operation.

Explains the infrastructure components that allow this open network to communicate seamlessly throughout a plant, from shop floor to top floor.

Provides collaborative design guidelines that are based on the Cisco Ethernet-to-the-Factory solution and the Rockwell Automation Integration Architecture solution.

Provides guidelines for troubleshooting an EtherNet/IP network, such as setting speed and duplex.

Contains specifications for the ControlLogix network communication modules.

Provides design considerations of network segmentation methodologies for the ControlLogix and CompactLogix™ 5370 controllers.

Describes the embedded software features and tools for configuring and managing the Stratix 5410, Stratix 5400, and the Stratix 5700 Ethernet managed switches.

Provides switch specifications, certifications, and the latest product information.

Illustration that shows options for connecting your plant network by using standard Ethernet technology.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 9

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Preface

Table 2 - Infrastructure Resources

Resource Description

ControlNet Coax Media Planning and Installation Guide, publication CNET-IN002

ControlNet Fiber Media Planning and Installation Guide, publication CNET-IN001

ControlNet Modules in Logix5000 Control Systems User Manual, publication CNET-UM001

Product Compatibility and Download Center at

http://www.rockwellautomation.com/ rockwellautomation/support/pcdc.page

Provides procedures for planning, installing, and implementing a ControlNet network.

Website helps you find product-related downloads including firmware, releas e notes, associated software, dri vers, tools and utilities.

Table 3 - Field Device Integration Resources

Resource Description

FactoryTalk AssetCentre Installation Guide, publication FTAC-IN005

FactoryTalk AssetCentre Product Profile, publication FTALK-PP001

EtherNet/IP and ControlNet to FOUNDATION Fieldbus Linking Device, publication 1788-UM057

1788-EN2PAR User Manual, publication 1788-UM056 Describes the installation and operation of the 1788-EN2PAR linking device.

1788-CN2PAR User Manual, publication 1788-UM055 Describes the installation and operation of the 1788-CN2PAR linking device.

ControlLogix HART Analog I/O Modules User Manual, publication 1756-UM533

Promass 83 Flowmeter via PROFIBUS PA to the PlantPAx Process Automation System, publication PROCES-AP022

DeviceNet System Quick Reference, publication DNET-QR001

CENTERLINE® Motor Control Centers with EtherNet/IP, publication 2100-TD031

CENTERLINE 2500 Motor Control Centers with EtherNet/IP Network, publication 2500-TD003

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

Provides installation instructions for monitoring your factory automation system.

Explains this tool for securing, managing, versioning, tracking, and reporting automation-related asset information across yo ur entire enterprise.

Describes the installation and operation of the 1788-EN2FFR and 1788-CN2FFR linking devices.

Contains information on how to install, configure, and troubleshoot ControlLogix HART analog I/O modules.

Provides procedures for the design and implementation of PROFIBUS PA equipment.

Provides procedures for configuring applications on the DeviceNet® network.

Describes cable system construction and components that are associated with an EtherNet/IP network that is factoryinstalled in CENTERLINE 2100 and CENTERLINE 2500 and IntelliCENTER® motor control centers (MCCs).

Provides a step-by-step approach to integrating HART devices from Endress+Hauser into the PlantPAx system.

Table 4 - Batch Resources

Resource Description

FactoryTalk Batch User's Guide, publication BATCH-UM011 Provides a complement of FactoryTalk recipe management, component guidelines, and software installation

FactoryTalk Batch Installation Guide, publication BATCH-IN002

PlantPAx Batch Design Considerations Reference Manual, publication PROCES-RM008

Batch Application Toolkit Quick Start, publication IASIMP-QS042

PhaseManager™ User Manual, publication LOGIX-UM001 Explains how to define a state model for your equipment and develop equipment phases.

10 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

procedures.

Provides information and procedures for installing FactoryTalk Batch software.

Provides guidance on selected batch implementation topics in a PlantPAx system.

Provides a framework for how to use the tasks to complete the components of the Toolkit.

Page 11

Table 5 - Process Safety Resources

Resource Description

Using ControlLogix in SIL 2 Applications Safety Reference Manual, publication 1756-RM001

Redundant I/O System User Manual publication 1715-UM001

AADvance Solutions Handbook, publication ICSTT-RM447

AADvance System Build Manual, publication ICSTT-RM448

AADvance Configuration Guide, publication ICSTT-RM405 Defines how to configure an AADvance controller by using the AADvance Workbench to meet your Safety Instrument

AADvance Safety Manual, publication ICSTT-RM446

AADvance Troubleshooting and Repair Manual, publication

ICSTT-RM406

ControlLogix components that are supported in SIL 2 configurations.

Describes how to install and configure the 1715 Redundant I/O system with a ControlLogix Enhanced Redundancy System.

Explains the features, performance, and functionality of the AADvance controller and systems. It sets out some guidelines on how to specify a system to meet your application requirements.

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

Function (SIF) application requirements.

Defines mandatory standards and makes recommendations to safely apply AADvance controllers for a SIF application. Explains how to use traditional and extreme environment ControlLogix controllers.

Provides plant maintenance personnel with information on how to trace and repair a fault in an AADvance system and perform routine maintenance tasks.

You can view or download publications at

http://www.rockwellautomation.com/literature

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Preface

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 11

Page 12

Preface

Notes:

12 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

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Chapter 1

EWS PASS

Domain Control ler

Application Servers Multiple OWS

Device Level Ring Topology

System Architecture Overview

The PlantPAx® system uses standard Rockwell Automation® Integrated Architecture® (IA) products to build a distributed control system (DCS). Our modern DCS is scalable, flexible, and open while still providing the reliability, functionality, and performance expected from a DCS.

This section describes the system elements and architectures that you can use to configure a PlantPAx system.

Top ic Pag e

Architecture Classes 14

System Elements 14

Critical System Attributes 15

System Procurement Tools 16

Rockwell Automation characterizes a DCS based on its size or architecture class. A ‘characterized’ classification yields system performance data and recommended hardware and software configurations.

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Chapter 1 System Architecture Overview

Station Architecture

Distributed Architecture- Multiple PASS Servers

Distributed Architecture- Single PASS Server

Skid Controller

Architecture Classes

Architecture classes define reference architectures that are based on the size of the required system.

Architecture Description

Skid Skid architecture with a skid controller and PanelView™ for monitoring data.

Station A single station that acts as a PlantPAx Automation System Server (PASS), Operator Workstation (OWS), and

Distributed - Single server This architecture has a single PASS server and supports multiple OWSs and EWSs.

Distributed - Multiple servers This architecture has multiple PASS servers and supports multiple OWSs and EWSs. You can add servers for more capacity or to

Engineering Workstation (EWS).

segregate servers by operating areas.

System Elements

System elements are the different elements of a PlantPAx DCS. Elements can be deployed on your system depending on the needs of the application.

Table 6 - Architectures and System Elements

System Element

PASS Not applicable. Single workstation serves as PASS, EWS,

EWS Included in independent workstation 1 EWS required. 1 EWS required.

Skid Architecture Station Architecture Distributed Architecture

(single PASS (consolidated))

and OWS in an independent workstation

For smaller systems, one PASS (consolidated) is required that typically includes the following:

• FactoryTalk® Directory server

• HMI server

• Data server

• Alarm and Event Server

The PASS-C supports functions that otherwise are hosted on application servers. The PASS-C single computer includes the following in a single workstati on:

• PAS S

• FactoryTalk Historian

• AppServ-Asset Management

• AppServ-VantagePoint

• AppServ-Info (SQL)

IMPORTANT: An additional PASS-C is

required for redundan cy.

Distributed Architecture (single to multiple PASS servers)

One PASS required and includes one or more of the following:

• FactoryTalk Directory server

• HMI server

• Data server

• Alarm and Event Server

Additional PASS as needed (up to 10 servers or redundant server pairs).

Can have as many as 5 EWSs.

(1)

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Table 6 - Architectures and System Elements

System Architecture Overview Chapter 1

System Element

OWS Not applicable. Operator

Controllers CompactLogix controller. 1...5 ControlLogix® controllers. 1...5 ControlLogix controllers.

Application servers

(1) These values are product maximum limits. It’s possible that achieving these limits on your system is not feasible based on your system design. Use the PlantPAx System Estimator to make sure that your

system is sized properly (see page 16

Critical System Attributes

Skid Architecture Station Architecture Distributed Architecture

(single PASS (consolidated))

interface typically accomplished with PanelView Plus operator terminal or thin client connected to a distributed architecture.

Not applicable. In chassis historian and in controller batch capabilities are available. Can also be integrated with a distributed architecture.

Included in independent workstation Included in PASS-C.

An .ISO file is available for any single, physical computer.

IMPORTANT: PASS-C supports up to 10 clients.

IMPORTANT: PASS-C supports up to five redundant contro llers.

Use the PlantPAx System Estimator to verify your design. See page 16

AppServ-Asset Management as needed. AppServ-Batch as needed. AppServ-Information Management (SQL,

Historian, or VantagePoint®) as needed.

Additional servers can be added as your system scales. For example, AppServ-Batch, AppServ-Information Management.

IMPORTANT: An additional PASS-C is required for redundan cy.

A critical system attribute (CSA) is a visible performance indicator of a

Distributed Architecture (single to multiple PASS servers)

Can have as many as 120 OWS clients.

There is no hard limit for the number of controllers. The number of controllers that can be supported per PASS (data server) depends on controller selection,

controller loading, and number of OWS.

AppServ-Asset Management as needed. AppServ-Batch as needed. AppServ-Information Management (SQL,

Historian, or VantagePoint) as needed AppServ-OWS as needed.

(1)

system-wide characteristic. CSAs are used to define or identify specified levels of system operation:

• Determine system limits

• Establish system rules

• Establish system recommendations

• Measure system element and system infrastructure performance

The following CSAs are used to verify performance during process system characterization.

Table 7 - CSA Performance Indicators

Critical System Attribute

Display callup (paint time) A noncached display is called up by the operator and ready for operator use within 2 seconds.

Display update The display updates control information within 1 second.

Steady state alarm time Steady state alarms occurring at 20 per second are timestamped within 1 second.

Alarm burst time All alarms in a burst of 1000 alarms are timestamped within 3 seconds.

Recovery A system element returns to full operation within 5 minutes of the restoration after a failure or loss.

Operator-initiated control Operator-initiated actions are loaded into the controller and the feedback for the operator action is within 2 seconds.

Batch server: operator action time An operator batch command has been acted on by the controller in 1 second.

Batch server: server action time A server batch command has been acted on by the controller in 1 second.

Batch server: controller action time Batch status events display on the operator workstation within 1 second.

(1) CSA performance indicators are a nominal per formance number. The actual system performance c an intermittently deviate from the documented CSA due to system disturbances that can introduce

variability in the network or operating system performance.

(1)

Performance

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Chapter 1 System Architecture Overview

System Procurement Tools

The following chapters of this manual contain recommendations and considerations for how to implement your system. If you have not selected or procured your PlantPAx system architecture and components, see the PlantPAx Selection Guide, publication PROCES-SG001

The PlantPAx System Estimator (PSE), which is a part of the Integrated Architecture® Builder (IAB) software tool, helps you define a PlantPAx system. The PSE wizard lets you specify your system architecture that is based on your requirements, and verifies that your process control hardware is sized properly.

When the verification is complete, you can transfer the output of the PSE wizard into the IAB tool to develop a bill-of-material for the system based on your inputs.

See http://www.rockwellautomation.com/en/e-tools/configuration.html access the IAB tool.

, for more information.

16 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

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Chapter 2

System Element Recommendations

PlantPAx® system elements refer to the individual servers, clients, and controllers that comprise a PlantPAx system. This chapter describes each system element and its components. A base installation of all server and workstation elements is available as virtual appliances.

The following table lists where to find specific information.

Top ic Pag e

PlantPAx Software Components 17

Process Automation System Server (PASS) 18

Engineering Workstation (EWS) and Application Server (AppServ-EWS) 20

Operator Workstation (OWS) and Application Server (AppServ-OWS) 21

Independent Workstation (IndWS) 23

AppServ-Info (Historian) 24

AppServ-Info (VantagePoint) 24

AppServ-Info (SQL) 25

Asset Management Server (AppServ-Asset) 25

Batch Management Server (AppServ-Batch) 26

Domain Controller 27

Controller Characteristics 28

PlantPAx Software Components

Integrated Architecture® software components and versions that comprise the PlantPAx system, include the following:

• Studio 5000 Logix Designer® application, version 31.x

• Studio 5000 Architect™ application, version 4.x

• FactoryTalk® View software, version 11.x

• FactoryTalk Batch software, version 13.x

• FactoryTalk AssetCentre software, version 9.x

• FactoryTalk® VantagePoint® software, version 8.x

• FactoryTalk Historian software, version 6.x

Performance guidelines are based on the use of the software versions listed.

For the latest compatible software information and to download associated library tools, see the Product Compatibility and Download Center at http://

www.rockwellautomation.com/rockwellautomation/support/pcdc.page.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 17

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Chapter 2 System Element Recommendations

Process Automation System Server (PASS)

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. The PASS can be used as a data, HMI, and/or alarm server.

Software Components Description

Fac toryTa lk Network Directory (FTD) server

FactoryTalk Activation server

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

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 ser ver 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)

Secures information from multiple Rockwell Automation® software components across multiple computers and provides 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 allows 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.

HMI server stores HMI project components, such as graphic displays, and serves these components to OWSs upon request. The HMI server also can manage tag databases and log historical data. Multiple HMI servers can exist on the PlantPAx system. 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 mention ed 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. There are two types of Alarm and Event servers: device-based and ser ver-based. Device-based Alarm and Event servers are configured as an option to the data server. Server-based Alarm and Event servers are configured as a separate component. Each server-based Alarm and Event server must be on a separate PASS.

The Alarm and Event server that is mentioned in PlantPAx documentation refers to the Alarm and Event server that is server-based. See Alarm System Recommendations on page 55 for more information.

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

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

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System Element Recommendations Chapter 2

IMPORTANT

PASS Server Redundancy

PASS servers can be configured as redundant for the following software components:

• HMI server

• Data server

• Alarm server

When you enable redundancy in FactoryTalk View Studio software, select the option to ‘Continue using the secondary server even when the primary server becomes available again’ to avoid excessive switchovers. This option lets you manage replication of application changes made before or after the switchover occurs. We recommend that you configure your HMI displays to indicate when the system is running without backup.

The FactoryTalk Directory server information is cached on each computer that is participating in a distributed application. If the FTD server computer is disconnected from the network or fails, the OWS, EWS, and other application servers can continue to access everything within the application. This functionality applies as long as the computer has already accessed the FTD server.

Table 8.1 - PA SS Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69.

• 4 vCPU

• 8 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

(1)

(2)

Table 8.2 - PASS Traditional Requirements

Category Requirement

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

• 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)

PASS - C (for small and medium systems) 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

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

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

• Intel® Xeon E-31270 v5

• 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)

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Chapter 2 System Element Recommendations

IMPORTANT

Configure the FactoryTalk Directory

Before starting a project, you must install FactoryTalk Directory (FTD) services on the computer that is hosting the FTD or the PASS. The FTD server manages applications that can exist on multiple clients and servers on separate computers on the PlantPAx system.

To configure the FTD, see the PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001

Engineering Workstation (EWS)

The EWS supports system configuration, application development, and maintenance functions. This workstation is the central location for monitoring and maintaining the system operation.

If a batch application server is used, the FactoryTalk Batch client and editor components are required to configure the FactoryTalk Batch system and configure the FactoryTalk objects on the displays.

Table 9.1 - EWS Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows 10 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

Table 9.2 - EWS Traditional Requirements

Category Requirement

Traditional infrastructure The EWS must be installed on workstation-class hardware. The following are sample specifications based on PlantPAx

Operating system Windows 10 operating system, 64 bit

on page 69

• 2 vCPU

• 4 GB vRAM min

• 100 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

system characterization.

• Intel Core 2 Duo

• 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)

(1)

(2)

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System Element Recommendations Chapter 2

Engineering Workstation Application Server (AppServ-EWS)

The AppServ-EWS uses Microsoft® Remote Desktop Services (RDS) technology to serve multiple instances of the EWS as thin clients from a single server. Thin clients can run applications and process data on a remote computer. The recommended limit is five RDS client connections per AppServ-EWS.

Table 10 - AppServ-EWS Virtual Requirements

Category Requirement

Virtual infrastructure Required:

• 4 vCPU

• 8 GB vRAM min

• 100 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

Thin client We recommend a maximum of 5 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 sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

Operator Workstation (OWS)

on page 69

The operator workstation (OWS) provides the graphical view and interface into

(1)

(2)

the process. The OWS supports operator interaction and is not meant to support development or maintenance activities, although these activities are possible if desired.

FactoryTalk View Site Edition (SE) client software must be installed on the OWS. The OWS also can contain clients for non-core application servers, such as FactoryTalk Batch, FactoryTalk Historian, or FactoryTalk AssetCentre.

Table 11.1 - OWS Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows 10 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

• 2 vCPU

• 4 GB vRAM min

• 40 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

Table 11.2 - OWS Traditional Requirements

Category Requirement

Traditional infrastructure The OWS must be installed on workstation-class hardware. The following are sample specifications based on PlantPAx

Operating system Windows 10 operating system, 64 bit

system characterization:

• Intel Core 2 Duo

• 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)

(1)

(2)

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Chapter 2 System Element Recommendations

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.

ThinManager

Remote Desktop Servers Virtual Resources

Operator Workstation Application Server (AppServ-OWS)

The AppServ-OWS uses Microsoft Remote Desktop Services (RDS) technology to serve multiple instances of the OWS as thin clients from a single server. Thin clients can run applications and process data on a remote computer. The recommended limit is 10 RDS connections per AppServ-OWS.

Table 12 - AppServ-OWS Virtual Requirements

Category Requirement

Virtual infrastructure Required:

• 8 vCPU

• 16 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

Thin client We recommend a maximum of 10 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 sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

(1)

(2)

ThinManager Server Options

The AppServ-OWS system element virtual image template is pre-configured with Remote Desktop Services (RDS). RDS 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 one easy-to-use, centralized, and scalable management platform

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System Element Recommendations Chapter 2

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 to manage computers

• Enhance visualization by delivering your content to where you need it and

the way you want the content 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, contact your Rockwell Automation representative.

Independent Workstation (IndWS)

Table 13 - IndWS Traditional Requirements

Category Requirement

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

Operating system Windows 10 operating system, 64 bit

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

PlantPAx system characterization:

• Intel Multicore processor (4 cores 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)

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Chapter 2 System Element Recommendations

AppServ-Info (Historian)

The Information Management server can include a historian application to collect, manage, and analyze data.

Table 14.1 - AppServ-Info (Historian) Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation (3) To install FactoryTalk View SE Historian software, version 4.6, with Windows Server 2016, you must install a patch from the Product Compatibility and Download Center at

http://www.rockwellautomation.com/rockwellautomation/support/pcdc.page

on page 69

• 2 vCPU

• 4 GB vRAM min

• 120 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

Table 14.2 - AppServ-Info (Historian) Traditional Requirements

Category Requirement

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

Operating system Windows Server 2016 operating system, 64 bit

• 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)

(1)

(2)

(3)

AppServ-Info (VantagePoint)

The Information Management server can be used as a decision support tool by installing VantagePoint software.

Table 15.1 - AppServ-Info (VantagePoint) Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69.

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

Table 15.2 - AppServ-Info (VantagePoint) Traditional Requirements

Category Requirement

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

Operating system Windows Server 2016 operating system, 64 bit

• 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)

(1)

(2)

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System Element Recommendations Chapter 2

AppServ-Info (SQL)

An SQL server can be configured with the Information Management server. Software such as FactoryTalk AssetCentre, FactoryTalk VantagePoint, and FactoryTalk Batch use an SQL database to store and access process data. Additionally, the FactoryTalk Alarm and Event server uses an SQL database to store information

Table 16.1 - AppServ-Info (SQL) Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69.

• 2 vCPU

• 4 GB vRAM min

• 120 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

Table 16.2 - AppServ-Info (SQL) Traditional Requirements

Category Requirement

Traditional infrastructure The Information Management server must be installed on ser ver-class hardware:

Operating system Windows Server 2016 operating system, 64 bit

• 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)

(1)

(2)

Asset Management Server (AppServ-Asset)

An asset management server (AppServ-Asset) is an extension to the PlantPAx system that adds maintenance and plant operations to the system. This server provides the following to improve resource availability:

• Disaster recovery controller data

• Diagnostics

• Calibration

• Real-time monitoring

• Auditing equipment

• Network health

Table 17.1 - AppServ-Asset Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(1)

(2)

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Chapter 2 System Element Recommendations

Table 17.2 - AppServ-Asset Traditional Requirements

Category Requirement

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

Operating system Windows Server 2016 operating system, 64 bit

• 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)

Batch Management Server (AppServ-Batch)

The batch management server (AppServ-Batch) offers comprehensive batch management, including recipe management, procedural control of automated and manual processes, and material management.

Table 18.1 - AppServ-Batch Virtual Requirements

Category Requirement

Virtual infrastructure Required:

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(1)

(2)

Table 18.2 - AppServ-Batch Traditional Requirements

Category Requirement

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

Operating system Windows Server 2016 operating system, 64 bit

• 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)

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System Element Recommendations Chapter 2

Domain Controller

A domain controller is a server that responds to security authentication requests (log in, verify permissions, and so forth) within the Windows server domain. A domain grants you access to a number of network resources (such as applications and printers) with the use of a single user name and password combination. PlantPAx uses a domain controller to store user account information, authenticate users, and enforce security policies.

Domain authentication is recommended, whether it’s an existing domain or a new one. Follow these guidelines for the domain controller:

• Domain controllers are required if there are 10 or more workstations or servers.

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

• Microsoft support does not recommend applications to be run on a domain controller, and certainly not applications that require more than Authenticated User privileges to run.

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

Table 19.1 - Domain Virtual Requirements

Category Requirement

Virtual infrastructure 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

(1)

(2)

(1) All numbers and figures are referenced for initial sizi ng only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69.

Table 20 - Domain Traditional Requirements

Category Requirement

Traditional infrastructure

Operating system Windows Server 2016 operating system, 64 bit

(1) A Microsoft Excel software license is required.

(1)

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)

For redundancy purposes, we recommend that you use at least two domain controllers in the domain. These domain controllers replicate automatically to provide high availability and an online configuration backup.

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Chapter 2 System Element Recommendations

Controller Characteristics

This section describes the components and sizing attributes for simplex, skid-based, and redundant controllers.

Simplex Controller

Non-redundant controllers are referred to as simplex controllers.

Table 21 - Simplex Controller Hardware Requirements

Category Cat. No.

Process controller

EtherNet/IP interface • For direct DLR connection: 1756-EN2TR

ControlNet interface (if applicable) • 1756-CN2, 1756-CN2R

(1) If environmental conditions warrant, you can use an extreme temperature controller, for example, the 1756-L74XT. Conformal coated options are also available for protection from harsh environments

that can contain moisture and or chemical contaminants.

(2) As the PlantPAx system release 4.6 uses controller firmware revision 31, implementation requires use of the 1756-L7x controller family. PlantPAx system release 4.6 can co-exist with older

generation contro llers.

(2)

(1)

ControlLogix® 1756-L71, 1756-L72, 1756-L73, or 1756-L74, or 1756-L75 controller

• For direct PRP connection: 1756-EN2TP

• For secure connections: 1756-EN2TSC

• Otherwise: 1756-EN2T, 1756-EN2F (no DLR support)

• For converting topology or media: 1783-ETAP, 1783-ETAP1F, 1783-ETAP2F (supports DLR topology)

• 1756-CNB, 1756-CNBR

Table 22 - Simplex ControlLogix Controller Sizing

(1)

Redundant Controllers

ControlLogix controllers support redundancy on ControlNet and EtherNet/IP networks. In a redundant controller system on PlantPAx, you need these components:

• Two 1756 chassis each set up the same with the following: – Number of slots – Modules in the same slots – Redundancy firmware revisions in each module – Two additional ControlNet or Ethernet nodes outside the redundant

chassis pair

• One 1756-RM2 module per chassis with fiber media

Table 23 - Redundant Controller Hardware Requirements

Category Cat. No.

Process controller ControlLogix 1756-L73, 1756-L74, or 1756-L75 controller

Redundancy module 1756-RM2

Ethernet interface • For direct DLR connection: 1756-EN2TR

• For direct PRP connection: 1756-EN2TP

• For secure connections: 1756-EN2TSC

• Otherwise: 1756-EN2T, 1756-EN2F (no DLR support)

• For converting topology or media: 1783-ETAP, 1783-ETAP1F, 1783-ETAP2F (supports DLR topology)

ControlNet interface (if applicable) • 1756-CN2, 1756-CN2R

• 1756-CNB, 1756-CNBR

(1) If environmental conditions warrant, you can use an extreme temperature controller, for example, the 1756-L74XT. Conformal coated options are also available for protection from harsh environments

that can contain moisture and or chemical contaminants.

(2) The PlantPAx system recommendation is to use only one redundant controller in a chassis with a 1756-RM2 redundancy module. While a 1756-RM2 module can support t wo controllers, the resulting

performance of each controller is not easily predicted.

(1)

(2)

Make sure that each redundant controller has enough memory to store twice the amount of controller data and I/O memory to support program modifications. The increased memory usage in a redundant controller provides for a bumpless transfer during a switchover and makes sure the secondary Logix controller has the same values in its output image as the primary Logix controller. The extra memory helps prevent a switchover to a secondary controller with a mixture of old and new data memory.

When using the PlantPAx System Estimator, the PSE accounts for additional memory requirements required for redundancy as memory used.

Table 24 - Redundant ControlLogix Controller Sizing

(1)

Skid-based Controller

The PlantPAx process automation system is a complete, scalable system, from single controller to a fully distributed set of equipment. You can easily integrate skid-based equipment into the overall system.

The CompactLogix™ controller platform offers a solution for skid-based equipment 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

Be aware of memory usage within the CompactLogix family when using Library objects. See the PlantPAx Distributed Control System Application Configuration User Manual, publication PROCES-UM003 for guidance of how to configure controllers with the Library of Process Objects.

Table 25 - Skid-based Controller Sizing

(1)

Determining I/O Count

The I/O count for controller sizing is often determined directly from the application P&ID or plant design. On existing systems where only classic I/O (for example, 4…20 mA, 24V DC dry contacts, and so forth) is used, the I/O count can be determined by the number of I/O channels available on the I/O cards.

When you have integrated smart devices, such as drives or transmitters, on an EtherNet/IP network, any signal from the device used by your control strategy is considered an I/O point when using the PSE to size based on control strategies.

For example, an I/O count for a system comprised with the following:

• Two 8-channel 4…20 mA input cards

• One 8-channel 4…20 mA output cards

• Two 16-channel 24V DC dry-contact input cards

• One MCC with six drives – Each drive provides six signals to the control strategy: speed reference,

actual speed, start, stop, running, and fault.

• Two Coriolis flowmeters on PROFIBUS PA, with each meter providing three signals for flow, temperature, and density.

We can roughly calculate the following I/O count for the example system:

4…20 mA AI 2 x 8 = 16 4…20 mA AO 1 x 8 = 8 24V DC DI 2 x 16 = 32 MCC 6 x 6 = 36 (6 AI, 6 AO, 12 DI, 12 DO) Smart instruments 2 x 3 = 6 (6 AI)

___

Controller I/O count 98

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 31

This example I/O count method enables you to enter I/O counts into the PSE to determine an appropriate number of control strategy footprints to determine sizing.

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Chapter 2 System Element Recommendations

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PASS/Application Servers

Process Information servers collect the process and system data for use in managing the process.

Operator interface presents system information to the user.

Controllers execute application code to control the process and communicate with the supervisory level.

Sizing Control Strategies

A control strategy encompasses all of the application code required to implement a specific control function. The application code includes the I/O, controller code, display elements, and faceplates.

The Rockwell Automation Library of Process Objects contains a Library of Process Strategies. The process strategies include control strategies for I/O processing, device control, and regulatory control.

Figure 2 - Control Strategy Example

Figure 2

shows devices that are being controlled and monitored in a loop via pre-engineered logic in Process objects. The object instructions in the controller send data to the HMI to visually evaluate on faceplates the function that is being performed.

By using the control strategy model, we are able to estimate the following system parameters:

• Potential alarms

• Visualization tags (affecting controller and server memory)

• Controller memory usage

• Controller execution time

32 Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019

By estimating the size of control strategies, you have a better prediction of system performance.

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System Element Recommendations Chapter 2

The amount of resources consumed by the system elements to support a control strategy provides a ‘footprint’. To size systems, these base control strategies are established as system footprints in the PSE:

•Simple regulatory: This strategy is a simple PID loop with a single analog input and analog output.

•Complex regulatory: This strategy is a more complex regulatory loop

Complex Regulatory — Primary (outer loop)

such as PID controllers in a cascade configuration with two analog inputs and one analog output.

There are two routines associated with the typical complex regulatory loop. Both routines are shown in the following examples.

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Chapter 2 System Element Recommendations

Complex Regulatory — Secondary loop (inner loop)

• Simple 2-state discrete: A simple valve or motor with interlock logic and

as single digital input and output.

• Complex 2-state discrete: A valve or motor with complex interlock, permissive, and runtime logic, which can have up to two digital inputs and two digital outputs.

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System Element Recommendations Chapter 2

• Complex regulatory non-PID: This strategy can be a complex control strategy, such as a loss in weight feeder, which can include an analog input, valves, and a motor.

• Digital indicator: A digital input that is used for indication and/or alarm only.

•Analog indicator: An analog input that is used for indication and/or alarm only.

The examples are not a comprehensive list of the types of strategies used in an application. But, the strategies do provide a reasonable set of examples that can be used to approximate the loading of the majority of typical application code.

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Chapter 2 System Element Recommendations

For each control strategy, we can estimate the footprint based on the following:

•Visualization Tags: The number of tags within the control strategy that can be visualized through a display or faceplate on the OWS (inclusive of operation, maintenance, and debug activities). This number affects server and controller memory utilization.

•Historian Tags: The number of tags within the control strategy that are typically brought into the historian. This number affects communication bandwidth, for example, active tags on scan/sec).

•# of Potential Alarms: The maximum number of alarms that can be defined. It is assumed that not every alarm is configured for use. The alarms that are used are configured in the server that contains the controller.

•Memory, KB: The amount of memory an instance of the control strategy and its associated tags uses inside of a simplex controller.

• Execution time (microseconds): The amount of controller CPU time it takes to run an instance of the control strategy under simulated loading (this is inclusive of the crossloading time for redundant controllers).

When a control strategy is instantiated, its impact to the controller is dependent on task rate for the task tat contains a control strategy. A PID loop running every 250 milliseconds takes twice the CPU capacity as the same PID loop running every 500 milliseconds.

Redundancy Considerations

If you are using redundant controllers, the scan rate and memory use increases 1.5…2 times.

When you look at controller memory, you do not see the total memory usage for redundancy. You need to calculate the actual memory that is used.

For more information, see the ControlLogix Enhanced Redundancy System User Manual, publication 1756-UM535

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Chapter 3

System Application Recommendations

This section contains integral information to configure controllers and other applications on your PlantPAx® system. We strongly recommend that you review these topics to be sure that the system is built and performing properly.

The following table lists where to find specific information.

Top ic Pag e

Controller Recommendations 38

FactoryTalk View Recommendations 52

Rockwell Automation Library of Process Objects 53

Additional Application Resources 54

Controller Recommendations

Logix controllers must be configured for optimal performance in process applications. From your EWS, follow these recommendations when configuring your controllers:

• Use periodic tasks only, with minimum number of tasks that are used to define execution speed, faster tasks getting higher priority (lower number).

• Set up monitoring of your controller utilization by using the L_CPU Add-On Instruction.

• Specify a requested packet interval (RPI) that is two times faster than task execution or based on inherent properties of the signal being measured. For example, a 500 ms task requires a 250 ms RPI on each I/O card, but temperature measurements can be set slower as they are unlikely to change that quickly.

• Limit the number of synchronous copy commands (CPS) as these commands act as an interrupt to the controller. Tasks that attempt to interrupt a CPS instruction are delayed until the instruction is done.

• Use Compatible Keying for configuring I/O module cards. However, in a validated environment that you can use an Exact Match for keying.

For more information, see Electronic Keying in Logix5000™ Control Systems Application Technique, publication LOGIX-AT001

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Chapter 3 System Application Recommendations

Ta b l e 2 6 shows memory and CPU recommendations for simplex and

redundant controllers.

Table 26 - Simplex and Redundant Controller Memory Recommendations

Environment Simplex Controllers Redundant Controllers

Outside of production environment (before connecting FactoryTalk® View and Historian clients)

In the production environment (while FactoryTalk View and Historian are connected)

50% free memory to support communication and handling of abnormal conditions

50% free CPU time to handle communication, abnormal conditions, and other transient loads

25% free memory to support handling of abnormal conditions

25% free CPU time 50% free CPU time

>50% free memory at all times

Task Configuration and CPU Utilization

The controller operating system is a preemptive, multitasking system that is IEC 61131-3 compliant. ControlLogix® and CompactLogix™ controllers define the schedule and priority of how programs are executed by using tasks.

Periodic Task Configuration

As we stated earlier, controllers that are configured for the PlantPAx system must use periodic tasks only. PlantPAx system sizing rules and tools are dependent on this specific execution configuration. For example, a controller is typically configured with three periodic tasks:

• Fast task (100…250 ms) for discrete control, such as motors and pumps

• Medium task (250…500 ms) for flow and pressure loops or analog inputs

• Slow task (1000…2000 ms) for temperature, phases, batch sequencing

As shown in Ta b l e 2 7 Studio 5000 Logix Designer® application in the order of execution period: fastest to slowest regardless of the tasks used. A dedicated task is created to monitor status of the controller and other tasks. We recommend that you delete tasks that are not used or create tasks that are required only by the application.

Table 27 - Recommended Task Configurations

Name Type Period (ms) Priority (lower number

Task_A_50ms Periodic 50 5 150 Unchecked

Task_B_100ms 100 6 300

Task_C_250ms 250 7 750

Task_D_500ms 500 8 1500

Task_E_1s 1000 9 3000

Task_F_2s 2000 10 6000

Task_G_5s 5000 11 15,000

Task_H_10s 10,000 12 30,000

_Controller_Status 1000 13 3000

, a naming convention is used so that tasks are listed in the

yields higher priority)

Watchdog (ms) Disable Automatic

Output Processing

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System Application Recommendations Chapter 3

Priority 1 100 ms Task Runs for 10 ms

Priority 2 500 ms Task Runs for 50 ms

Priority 3 1000 ms Task Runs for 200 ms to Finish

100

200

10 ms (10%)

50 ms (10%)

200 ms (20%)

300 400 500 600 700 800 900 1000

Each task that exists and is not inhibited has execution overhead. For sizing the PlantPAx system, we estimate this overhead as 1000 μs per task. The PSE calculates CPU utilization by calculating the required CPU time for the selected quantity of control strategies in each task.

Although a project can contain multiple tasks, the controller executes only one task at a time. If a periodic or event task is triggered while another task is executing, the priority of each task tells the controller what to do. Make sure that your periodic task priorities are unique.

We recommend that the total execution time of all tasks is less than half the execution time of the lowest priority task or slowest task. For example, a fast loop in a 100 ms task that executes every 10 ms., your other code could not be greater than 50 ms.

Figure 3 - Task Execution Example

As shown in Figure 3

, when you add the percentage for each task, the total

is 40% (10 + 10 + 20), which is less than 50% of the slowest task.

Follow these guidelines for task execution:

•Never use continuous tasks. Use periodic tasks only, with minimum number of tasks used to define execution speed, faster tasks getting higher priority (lower number).

A continuous task is created by default in the Studio 5000 Logix Designer application. This continuous task must be deleted. If left as the default, the continuous task runs in the background of the controller as the lowest priority task. Any controller CPU time that is not allocated to other operations or tasks is used to execute the continuous task.

When the continuous task completes, it restarts automatically and can be stopped only by a system overhead time slice. The system overhead time slice defines the amount of time the controller has available for communication. Thus, an overhead time slice interrupts the continuous task for communicating to HMI devices, processing MSG instructions,

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 39

and alarm instruction processing.

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Chapter 3 System Application Recommendations

This function limits the flexibility of the controller to apply resources to handle abnormal conditions in communication. However, the overhead time slice is ignored when a continuous task is not configured.

• Removal of the continuous task:

– Improves predictability of the controller CPU availability for

communication to the system

– Provides a more accurate view of the controller loading at runtime.

With continuous task, controller loading is always 100%

– Reduces the amount of task switching that improves overall application

and system performance

• Time-based operations, such as a PID algorithm, do not function accurately when run in a continuous task

• Do not use more than three periodic tasks to maintain optimum CPU performance. Batching can require more tasks, but we recommend that periodic tasks be event tasks if not in a redundant controller.

Estimate Controller CPU Utilization

The PSE uses a sizing model to estimate controller CPU utilization in a production environment. This calculation is as follows:

• Task Execution time is 1000 μs + sum of control strategy execution times assigned to the task

• Total controller execution time is a summation of task execution times normalized to the slowest task. For example:

250 ms Task Execution Time * 4 + 500 ms Task Execution Time * 2 +

1000 ms Task Execution time (if using 3 tasks: 250 ms, 500 ms, and 1000 ms)

• Tasks without assigned control strategies are ignored. It is assumed that these tasks are not created or are inhibited in the controller.

• CPU utilization is a percentage of the controller execution time/slowest task rate

Higher priority tasks interrupt lower priority tasks if needed to run. When the task interrupted is in progress, we call this task switching. A task switch adds execution overhead as well. If your faster tasks have higher priority, task switching does not occur in properly sized controllers. (A properly sized controller is when the total execution time of all of the tasks is less than half of the fastest task rate.) Hence, the PSE sizing model does not account for task switching when estimating utilization.

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System Application Recommendations Chapter 3

When periodic tasks have the same priority, the controller task switches every 1 ms until tasks are completed, each switch adding 250 -> 25 μs. This functionality is why it’s important that periodic tasks are given separate priorities. In Logix, you have up-to 15 user-defined priorities.

Keep in mind we want CPU load in a production environment to be 75% or less for a Simplex controller. For a redundant controller, we want CPU load in a production environment to be 50% or less.

It's important to keep 25% CPU capacity as reserve to handle online edits, data server switchover, and so forth. The PSE provides a warning when the calculated CPU load approaches the stated limits.

A task overlap is when a task is interrupted too frequently or too long that it doesn’t complete its execution before it is triggered again. Avoid task overlaps that can be monitored by using the L_TaskMon Add-On Instruction.

For more general information on ControlLogix execution capabilities, see the Logix5000 Controllers Design Considerations Reference Manual, publication 1756-RM094

CPU Utilization Example Estimations

The following examples show how configuration affects the sizing model and actual CPU utilization. For all scenarios, we are assuming a simplex 1756-L7x controller that is running 80 PID loops (800 μs execution per loop).

Example 1: 80 PID loops in a single periodic task @ 100 ms:

Task Execution Time: 1000 μs + (80 PID loops * 800 μs) = 65,000 μs

CPU = 65,000 μs /100,000 μs = 65% load

Example 2: 80 PID loops evenly split for two periodic tasks, first @ 50 ms, second @ 250 ms:

Task 1 Execution Time: 1000 μs + (40 PID loops * 800 μs) = 33,000 μs

Task 2 Execution Time: 1000 μs + (40 PID loops * 800 μs) = 33,000 μs

Total Execution per 250 ms = ((33,000 μs *5)+33,000 μs) = 198,000 μs

CPU Utilization: 198,000 μs / 250,000 μs = 79.2%

In this scenario, loading is not okay (> 75%). However, this example matches the PSE calculation that gives you a warning.

Example 3: Loops evenly split to 10 periodic tasks @ 100 ms and different priorities:

Task Execution per task: 1000 μs + (8 PID Loops * 800 μs) = 7400 μs

Total Execution time: 10 * 7400 μs = 74,000 μs

CPU = 74,000 μs / 100,000 μs = 74%

In this example, loading is near the desired limit but still okay (<75%). The PSE assumes proper task configuration, but it doesn’t account for the impact of the additional task overhead or the task switching (approximate 20% increase in CPU load).

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Chapter 3 System Application Recommendations

IMPORTANT

The goal of the PlantPAx system recommendations and PSE is to make it simple to size the system and provide assurance that everything works as expected. This is a critical need. While the examples are simple; they illustrate how configuration can impact load.

Monitor Controller CPU Utilization

Free process controller CPU time is required to handle communication, abnormal conditions, and other transient loads. Therefore, it’s important to consider CPU utilization when implementing the application code.

When defining the application code, make sure that the CPU utilization of the process controller can accommodate these values:

• In the development environment, CPU utilization is recommended to be less than 50% to allow for the additional CPU load that is experienced in the production environment.

• During the operation of the system, monitor the CPU utilization, especially after a change to the application code, and it cannot exceed 75% for a Simplex controller or 50% for redundant controllers.

• During the design of the application code, it’s important to account for software components, such as FactoryTalk View or Historian. The software is actively collecting data from the controller so be sure that CPU utilization is less than stated limits to allow for communication with the supervisory system elements (EWS, OWS, Information server).

There are two options for reviewing controller loading:

• Task Monitor - Available from the Studio 5000 Logix Designer application on the EWS. If more than one task monitor is viewing a controller simultaneously, its possible controller data is not reporting correctly.

• Logix Controller CPU Utilization (L_CPU) Add-On Instruction - See the Rockwell Automation Library of Logix Diagnostic Objects Reference Manual, publication PROCES-RM003

The L_CPU instruction is the preferred method to monitor controller performance because the logic monitors the Logix controller that is being executed. The controller is used in place of, or in addition to, the task monitor to provide more system-specific controller loading information.

Controller loading includes controller CPU utilization, communication usage, memory usage, and task scan times. This data provides information for diagnosing communication, controlling responsiveness issues, or in tuning the performance of control tasks for optimum controller performance.

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Figure 4 - CPU Utilization

6.67%

34.90%

0.24%

39.77%

220 Packets/Second

Application Code

Execution (user)

System

Null Time

100 ms Task

250 ms Task

500 ms Task

System Processing Time

System Background Tas k T ime

Comms IO Monitor

18.42%

Comms

IMPORTANT

System Application Recommendations Chapter 3

The diagram in Figure 4 shows a properly loaded Simplex controller for the following:

• Application code execution is less than 50% CPU

• Total execution including comms is less than 75% CPU

For more information, see the Rockwell Automation Library of Logix Diagnostic Objects Reference Manual, publication PROCES-RM003

Use of Program Parameters

The number of program parameters—Input, Output, InOut, Public —are limited to 512 parameters per program.

Input and Output parameters define the data that is passed by value into or out of an executing program. Because these parameters are passed by value, their value cannot change during the execution of the program.

We recommend that you use program parameters to exchange data between your programs and between programs and I/O. Program parameters simplify I/O mapping and can be modified online.

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Chapter 3 System Application Recommendations

Tag and Memory Allocation

Ta b l e 2 8 shows the memory of a controller is divided into several areas depending

on the type of controller.

Table 28 - Controller Memory Allocation

Controller Type Storage Memory

1756 ControlLogix 1768 CompactLogix

1769-L2x Compac tLogix 1769-L3x Compac tLogix 1769-L19x Compac tLogix

I/O tags I/O memory

Produced/consumed tags

Communication via message (MSG) instructions

Communication with workstations

Communication with polled (OPC/DDE) tags that use RSLinx® software

Tags other than I/O, produced, or consumed tags Data and logic memory

Logic routines (for example, control strategies)

Communication with polled (OPC/DDE) tags that use RSLinx® software

UDT and Add-On Instruction definition

These controllers do not divide their memory. They store all of the elements in one common memory area

(1)

(1) To communicate with polled tags, the controller uses both I/O data and logic memory.

When you configure displays, we recommend that you use direct tag referencing to access data from the controller directly without creating an HMI tag. This requires fewer configuration steps and is easier to maintain.

Use DINT and REAL data types whenever possible. Mathematical routines in the controller consume less CPU resources when DINT and REAL data types are used.

A user-defined data type (UDT) or Add-On Instruction data type lets you organize data to match your machine or process. Additional advantages of using a UDT or an Add-On Instruction include the following:

• One tag contains all the data related to a specific system activity. This keeps related data together and easier to locate, regardless of its data type.

• Each individual piece of data (member) gets a descriptive name. This automatically creates an initial level of documentation for your logic.

• You can use the data type to create multiple tags with the same data layout.

For example, you can use a UDT to store all the parameters for a tank, including temperatures, pressures, valve positions, and preset values. Create a tag for each of your tanks based on that data type.

You can create a UDT when online or offline. However, you can modify an existing UDT definition when offline only.

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System Application Recommendations Chapter 3

General Recommendations

• Define tags in arrays and a UDT whenever possible. Tag data that is packed into an array is sent more efficiently to the HMI than if you were using scattered tag data.

• When defining a UDT, group BOOL tags together whenever possible. Inside the controller memory, BOOL tags must align on 8-bit boundaries. But, if they are placed adjacent to each other they can share bytes and use less memory and communication bandwidth.

• BOOL data types that are not members of an array or structure use 4 bytes of controller memory. When communicating multiple BOOL tags between controllers or to displays, use a UDT or array to consolidate multiple BOOL tags into a single word.

• Define a tag naming convention that minimizes the length of the tag names. Long tag names can decrease the bandwidth available for communicating data.

For more information, see the Logix5000 Controllers I/O and Tag Data Programming Manual, publication 1756-PM004

Estimate Controller Memory Utilization

The PSE uses a sizing model that is based on control strategies to estimate controller memory utilization in a production environment. There are three sources of memory that comprise this sizing model:

• Memory for base definitions - Base definition memory varies depending on the amount of Add-On Instruction and UDT definitions in the project. Loading all of the Rockwell Automation Library definitions takes over 1 MB of memory, while loading the most common objects take much less memory. By default, the PSE assumes a base load of 380 KB. This is adjustable in the PSE system preferences, if needed.

• Memory used by control strategies - See Monitor Controller CPU

Utilization on page 42.

• Memory to support communication - The defined control strategies have a number of visualization tags for each control strategy (inclusive of operation, maintenance, and debug activities). During operation, the controller uses controller memory to manage the connections to these tags as they are accessed. The amount of memory used varies, but the PSE estimates 16 bytes per tag.

When controller redundancy is used, memory usage increases and additional spare capacity is required to allow for runtime edits. The PSE sizing model accounts for these needs by increasing the estimated amount of memory.

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Chapter 3 System Application Recommendations

Controller Properties icon

Estimate Memory Information Offline

To estimate how much controller memory your project requires, use the Capacity tab of the Controller Properties dialog box. For each of the memory areas of your controller, the dialog box provides an estimate number of bytes for the following:

• Free (unused) memory

• Use d memory

• Largest free contiguous block of memory

1. From the Studio 5000 Logix Designer application, click the controller

properties icon to access the Controller Properties dialog box.

2. Click the Capacity tab.

In the ‘Estimated Data and Logic Memory’ section, view the memory information since the last estimate.

3. Click Estimate to re-estimate the amount of controller memory.

View Runtime Memory Information

When online with a controller, the Capacity tab shows the actual memory usage of the controller. While the controller is running, it uses additional memory for communication. The amount of memory the controller needs varies depending on the state of the communication.

The Capacity tab of the controller includes a Max Used entry for each type of memory. The Max Used values show the peak of memory usage as communication occurs.

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Click Reset All Max on the Capacity tab to reset values.

For more information, see Chapter 2 in the Logix5000 Controllers Information and Status Programming Manual, publication 1756-PM015

Monitor Controller Memory Utilization

We recommend that 50% of available logic and data memory to be reserved for design time of communication, online editing, and handling of abnormal events. For simplex controllers, we recommend maintaining 25% of available logic and data memory to handle online editing and connection handling in operation.

For redundant controllers, we recommend that you maintain greater than 50% of logic and data memory available to handle online changes.

Memory usage can be monitored by using the L_CPU Add-On Instruction (see page 42

) or the Studio 5000 Logix Designer application (see page 46).

Controller-to-Controller Communication

There are two ways to set up communication between controllers:

• Produced/consumed tags

• Messages

Table 29 - Compare Messages and Produced/Consumed Tags

Method Benefits Considerations

Read/write message • Programmatically initiated

• Communication and network resources used when needed only

• Support automatic fragmentation and reassembly of large data

packets, up to as many as 32,767 elements

• Some connections can be cached to improve retransmission time

• Generic CIP™ message useful for third-party devices

Produced/consumed tag • Configured once and sent automatically based on requested

packet interval (RPI)

• Multiple consumers can simultaneously receive the same data from a single produced tag

• Can trigger an event task when consumed data arrives

• ControlNet resources are reser ved up front

• Does not impact the scan of the controller

• Delay can occur if resources are not available when needed

• MSG instruction and processing impacts controller scan (system

overhead time slice)

• Data arrives asynchronous to program scan (use a programmatic handshake or an UID/UIE instruction pair to reduce impact, no event task support)

• Can add additional messages online in Run mode

• Support limited to Logix5000 and PLC-5® controllers, and the

1784-KTCS I/O Linx and a few third-party devices

• Limited to 500 bytes over the backpl ane and 480 bytes over a network

• Must be scheduled when using ControlNet

• Data arrives asynchronous to program scan (use a programmatic

handshake or CPS instruction and event tasks to synchronize)

• Connection status must be obtained separately

• On an EtherNet/IP network, you can configure produced/

consumed tags to use multicast or unicast connections

• Cannot create additional produced/consumed tags online in Run mode.

We recommend that you use an array or user-defined tag for produce-consume communication. As produce/consumed tags cannot be edited online, make sure

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Chapter 3 System Application Recommendations

to include extra capacity that can be populated by mapping logic so additional information can be shared as needed without requiring a download.

Table 30 - Process Controller Recommendations

Category Recommendation

Produced and consumed tags • A single produced and consumed tag can contain multiple combinations of data. For example, up to 120 REALs

Messaging • There is a maximum of 32 cached message connections from message instructions and block transfers combined.

or 100 REALs and 640 BOOLs.

• Group produced and consumed tags into a user-defined structure to reduce the number of connections to the controller.

• Use the same data type for the produced and consumed tags in each controller that uses that data.

• Make sure the number of consumers configured for a produced tag is the ac tual number of controllers consuming it

to reduce the number of connections to the controller.

• On produced tags, the maximum consumers configured counts against your total connection count so make it the actual number of connections or set it at the expected number to be in the future.

• Always use a handshake when transferring data between controllers through health data or manually configured diagnostics.

• Cache messages when the message needs only to be maintained al l the time. If a message instruction is infrequent, then make sure cached connection is unchecked.

• Always use message reads, never do message writes. This makes it easier to troubleshoot code.

• When messaging between controllers, use DINTs where possible.

• Message instructions consume a connection when it is a CIP data table read, write, or generic (if selected).

Controller I/O Considerations

The requested packet interval (RPI) is a user-configured interval of time that determines when the data from an I/O module is sent to a controller. This interval defines the slowest rate that a module multicasts its data. When the specified time frame elapses, the module multicasts data to the controller.

Setting the RPI faster (specifying a smaller number) than what your application needs wastes network resources, such as ControlNet schedule bandwidth, network processing time, and CPU processing time.

Table 31 - I/O Considerations

Category Consideration

I/O configuration properties • Specify an RPI that is two times faster than task execution:

ControlNet network • Set the network update time (NUT) equal to or less than the fastest RPI of the I/O modules and produced-consumed

EtherNet/IP network See Chapter 5 for infrastructure recommendations.

– 250 ms task requires a 125 ms RPI – 100 ms task requires a 50 ms RPI

• Often RPI defined by the inherent properties of the signal being measured. For example temperature measurement

changes slower than pressure.

• Use compatible module for keying option on I/O cards configuration. In a validated environment, you can use an exact match for keying.

tags in the system. For example, if your fastest RPI is 10 ms, set the NUT to 5 ms for more flexibility in scheduling the network.

• Set the RPI to a binary multiple of the NUT. For example, if the NUT is 10 ms, select an RPI such as 10, 20, 40, 80, 160 ms, and so forth.

• Use unscheduled I/O to be able to add ControlNet modules at runtime. (See I/O Module Runtime/Online

Consi deration s.) Dedicate one ControlNet network to I/O communication only.

• Unscheduled I/O requires a connection to each module, so the number of modules supported depends on the number of connections supported by the communication module. On the dedicated I/O network, make sure of the following:

– No HMI traffic – No MSG traffic – No programming workstations – No peer-to-peer interlocking in a multi-processor system architecture

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I/O Module Runtime/Online Considerations

Ta b l e 3 2 shows some of the modules that you can add to the Controller

Organizer in the Logix Designer application when the controller is in Run mode.

Table 32 - Online Addition of Module and Connection Types

System Application Recommendations Chapter 3

Module Type and Connection Method

Motion - direct Yes No N/A N/A N/A N/A N/A N/A N/A

Digital - direct Yes Yes Yes Yes No Yes Yes Yes Yes - 1756 I/O digital

Digital - rack-optimized N/A N/A Yes No Yes No Yes Yes Yes - 1756 I/O digital

An alog - dir ect Yes Yes Yes Ye s No Yes Yes Yes Yes

Ge ne ric th ird -pa rt y - dire ct Yes Yes Yes Ye s No Yes Yes Yes N/A

1756-DNB Yes No Yes No No No Yes Yes N/A

1756-DHRIO Yes No Yes No No No Yes Yes N/A

1756-CNx - no connection Yes Yes Yes Yes No Yes N/A N/A N/A

1756-CNx - rack-optimized N/A N/A Yes N/A N/A N/A N/A N/A N/A

Generic ControlNet third-part y

- direct

1788HP-EN2PA-R N/A N/A N/A N/A N/A N/A Yes Yes N/A

1788HP-CN2PA-R N/A N/A Yes Yes No Yes N/A N/A N/A

1715 Redundant I/O No No No No No No Yes Yes N/A

1756-ENx - no connection Yes Yes N/A N/A N/A N/A Yes Yes N/A

1756-ENx - rack-optimized N/A N/A N/A N/A N/A N/A Yes Yes N/A

Generic EtherNet/IP third-party - direct

1794 FLEX™ I/O N/A N/A Yes Yes No No Yes No Yes - Analog output

1734 POINT I/O™ N/A N/A Yes Yes No No Yes No Yes

In Local Chassis Remote Via a ControlNet Network Remote Via an

EtherNet/IP Network

Offline Runtime Offline Runtime Offline Runtime

Scheduled Unscheduled Scheduled Unscheduled

N/A N/A Yes Yes No Yes N/A N/A N/A

N/A N/A N/A N/A N/A N/A Yes Yes N/A

Configure Hold Last Output State

output modules

modules only

(1)

(1) When you lose communication to the controller, POINT I/O™ ignores the last output state configuration, and sets the outputs to zero.

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When you design your network, review these considerations if you are going to add I/O modules at runtime.

Table 33 - Adding I/O Modules at Runtime

Category Consideration

I/O modules Currently, 1756 I/O and 1715 modules can be added at runtime.

Leave space in the local chassis, remote chassis on a ControlNet network, or remote chassis on an EtherNet/IP network for the I/O modules that you want to add.

Input transmission rate Make sure each RPI works for the data you want to send and receive.

Make sure the added I/O does not depend on change of state data. When adding discrete input modules, unselect Change of State to reduce network traffic.

Network topology On a ControlNet network, install spare taps so you can add 1756 I/O modules at runtime and not disrupt the network.

Network configuration On a ControlNet network, plan communication that can be scheduled or can be unscheduled.

Network performance You can add I/O modules at runtime until you impact the capacity of the communication module. Make sure that you

Each tap must be terminated so as not to ground out the system. Check the ControlNet system requirements to determine how many spare taps your network can support.

• In a ControlNet network with redundant cabling, you can break the trunk and add a tap, but redundant cabling is lost during the module installation.

• In a ControlNet ring, add a new drop off the rung or add new nodes off the coax and disrupt only part of the network.

• You could remove a single existing node and add a repeater off the drop. Then read the existing node and add any new nodes off of the new segment.

On EtherNet/IP, reser ve some connection points on the switch so that you can connect additional nodes or switches in the future.

On an EtherNet/IP network, all communication is Immediate and occurs based on a module’s RPI (also referred to as unscheduled).

If you know that you need a new chassis with digital modules in the future, configure the network and add it to the I/O configuration tree as rack-optimized. Inhibit the communication adapter until you need the chassis.

have sufficient communication modules for the connections you plan to add.

See the Logix5000 Controllers Design Considerations Reference Manual, publication 1756-RM094

, for more information.

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Using Add-On Instructions

Add-On Instructions are reusable code objects that contain encapsulated logic. Each object is provided as an importable Add-On Instruction that can be shared between projects to create a common library of instructions to accelerate engineering from project to project. Add-On Instructions also can be signed with a specific date and time, so that revisions of Add-On Instructions can be managed between projects.

This functionality lets you create your own instruction set for programming logic as a supplement to the instruction set provided natively in the ControlLogix and CompactLogic firmware.

Add-On Instructions are defined once in each controller project, and can be instantiated multiple times in your application code as needed. In the Studio 5000 Logix Designer application, you can view routines within an Add-On Instruction instance online, animated with just the instance value as if it were an individually defined routine.

Add-On Instructions can be source protected. Source protection does not let you edit the definition of an instruction without a source key. To protect intellectual property, routines and local tags also can be hidden on protected Add-On Instructions.

Like a native instruction, the definition of an Add-On Instruction cannot be modified online. Therefore, we do not recommend the use of Add-On Instructions to implement control strategies. Control strategies are best developed in a program, built from Add-On Instructions, and native instructions. It’s also important that you fully test all configuration options before implementing an Add-On Instruction on your production system.

The Rockwell Automation Library of Process Objects uses Add-On Instructions. For related information, see page 53

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FactoryTalk View Recommendations

For implementing FactoryTalk View SE software for a process system operator interface, follow these guidelines:

• Run FactoryTalk View Studio software on the EWS during runtime.

• Configure the FactoryTalk View SE servers to start automatically on

startup on the PASS. Let the servers fully start up before starting the client computers.

• In FactoryTalk View Studio software, areas can be used to organize your distributed system. Configure an area for each server of any type. Areas can contain areas. However, do not put more than one server in the root location of an area. This helps prevent potential performance problems. In addition, this name hierarchy can be visible externally, such as in the historian or alarm database.

• Use global objects to display the status of a control module or device when the information to be displayed is stored in a tag structure within Logix (for example, UDT or Add-On Instruction) and there are many identical instances. A global object is a display element that is created once and can be referenced multiple times on multiple displays in an application. When changes are made to the original (base) object, the instantiated copies (reference objects) are automatically updated. Use of global objects, in conjunction with tag structures in the ControlLogix system, can help to make sure of consistency and save engineering time.

• When using global objects, observe the following recommendations to be sure of optimal display call-up performance:

– Base global objects are stored in FactoryTalk View in displays (.ggfx

files). If you have a large number of base global objects defined, do not put them all in a single display. Limit the number of global object instances on a single display to 60 or less.

– As global objects can be instantiated multiple times, the performance

impact of their design is amplified by their number of instances. Therefore, design global objects carefully to reduce the number of objects, expressions, and animations that are used within the base object.

• We do not recommend the use of data logs. If necessary, use data logs for short-term data retention only.

• Do not create derived tags that depend on the results of other derived tags. Derived tag processing is not sequential.

• Avoid use of VBA when possible. VBA runs as a single-threaded process so it’s possible the application written in VB does not allow the HMI to perform predictably.

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Step 1: Import the Library into the project.

Step 2: Drop and configure the Add-On Instruction.

Step 3: Drop the global object on the display and assign it to an Add-On Instruction instance.

Step 5: Access the full faceplate from the global object at Runtime for control, maintenance, and configuration.

Step 4: Access small footprint ‘quick’ faceplates from the global object at Runtime for basic operator control.

Rockwell Automation Library of Process Objects

The Rockwell Automation Library of Process Objects is a predefined library of controller code (Add-On Instructions), display elements (global objects), and faceplates that let you quickly assemble large applications with proven strategies, rich functionality, and known performance.

The PlantPAx Distributed Control System Application Configuration User Manual, publication, PROCES-UM003,

describes how to import the process

strategies and map them to I/O by using program parameters.

The Library of Process Strategies helps you do the following:

• Makes sure of characterized performance with known control strategy configurations

• Reduces implementation time

• Promotes consistent applications and user experience

When coupled to display elements and faceplates in the FactoryTalk View Studio software program, these objects streamline device configuration in a drag-and-drop environment (as shown in the illustration).

The display elements (global objects) have an associated faceplate that appears when the display element is clicked. These faceplates let you operate and configure the instructions. When additional support functions are added, such as interlocks or permissives, the faceplates for these extended functions are directly accessible for the faceplate of the associated object.

The Rockwell Automation Library of Process Objects includes a Library of Process Strategies. Process strategies are pre-connected routines that use Rockwell Automation Library of Process Objects in the context of their intended use. The Library of Process Strategies includes routines for I/O processing, device control, and regulatory control.

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The Library of Process Objects is supported through Technical Support as long as the Add-On Instructions have not been modified from the original deployment.

You can use library objects other than objects provided by Rockwell Automation. For example, you can develop your own library or use the process objects as guides. By using a library of consistent elements from Rockwell Automation, you improve the maintainability and efficiency of your PlantPAx system.

For details on how to initiate objects and HMI displays, see the Rockwell Automation Library of Process Objects Reference Manual, publication

PROCES-RM002

Additional Application Resources

Topics and Tools Description Where To Find Information

System deployment guide Provides procedures that are necessary to start

FactoryTalk Diagnostic sample displays Sample graphics to display FactoryTalk Linx

Server status displays Sample code is provided to determine a server’s status

Rockwell Automation Integrated Architec ture® tools These tools can assist you in understanding, planning, and

Rockwell Automation sample code Sample code and tools for configuring and programming

Batch implementation tools Videos, documentation, and sample code to help

The following resources are available for use to assist with developing your application.

development of your PlantPAx system.

sample counters.

and state by using VBA and displaying the status on the HMI display.

configuring an Integrated Architecture System.

Rockwell Automation products, including Rockwell specific faceplates.

guide you to the best design decisions for batch system implementation.

See the PlantPAx Distributed Control System Application Configuration User Manual, publication PROCES-UM003

See the Knowledgebase Answer ID 30148 at

http://rockwellautomation.custhelp.com

See the Knowledgebase Answer ID 44624 at

http://rockwellautomation.custhelp.com

http://www.rockwellautomation.com/solutions/ integratedarchitecture/resources.html

http://samplecode.rockwellautomation.com/idc/groups/ public/documents/webassets/sc_home_page.hcst

See the Batch Application Toolkit Quick Start, publication IASIMP-QS042

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Chapter 4

Alarm System Recommendations

In the process industries, alarms are a critical function of a control system. Effective alarm systems alert the operator to abnormal situations, providing for a quick response. Effective alarm handling improves the productivity, safety, and environment of a process plant.

There are industry standards that govern alarm management design and engineering practices. The standards help you develop effective alarm systems (for example ANSI/ISA-18.2, Management of Alarm Systems for the Process Industries). This section does not cover the practices that are defined by these standards. We provide recommendations for implementing alarms on the PlantPAx® system within the context of these standards.

The following table lists where to find specific information.

Top ic Pag e

FactoryTalk Alarm and Event Software 55

Using the Library of Process Objects for Alarms 59

Alarm State Model 60

Monitoring Your Alarm System 63

FactoryTalk Alarm and Event Software

The primary method for generating alarms in the PlantPAx system is FactoryTalk® Alarm and Event software, herein referred to as the alarm system. The alarm system supports device-based alarms (ALMA and ALMD instructions in the controller) and tag-based alarms (digital, level, or deviation alarms).

Device-based and tag-based alarms co-exist in an application. PlantPAx system sizing rules and critical system attributes are based on the use of tag-based alarms. While device-based alarms can be used, we recommend limiting their use to enhance system performance.

See page 57

for more information.

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Chapter 4 Alarm System Recommendations

Figure 5 - FactoryTalk Services Platform

Alarm Characteristic Description

1. Tag-based alarm monitoring Tag-based alarms (digital, level, or deviation) are configured in a Tag Alarm and Event server. When an alarm condition is detected by a

2. Device-based alarm monitoring The PlantPAx system sizing rules and Critical System Attributes are based on the use of FactoryTalk Alarm and Event tag-based alarms.

3. FactoryTalk Alarm and Event services Both device-based and tag-based alarms and events are published to FactoryTalk Alarm and Event services. The Alarm and Event services

4. Alarm and Event log The Alarm and Event log is a component that installs silently as part of the alarm and event software. It manages connections between

5. Alarm and event setup and monitoring FactoryTalk Alarm and Event includes a number of software components that let engineers and operators to do the following:

controller, the server publishes the information to FactoryTalk Alarm and Event services.

While device-based alarms can be used, we recommend a limited usage to enhance system performance. Device-based alarms, such as ALMA, ALMD, are programmed via Studio 5000 Logix Designer® and then downloaded to Logix5000™ controllers. The controller detects alarm conditions and notifies FactoryTalk Linx of alarm states. A Rockwell Automation® device server (FactoryTalk Linx software) extracts the alarm information and publishes it to FactoryTalk Alarm and Event services.

routes the information to FactoryTalk Alarm and Event objects that are hosted in FactoryTalk View software. The information also routes to the alarm and event history log, and to diagnostic logs and audit logs.

alarm servers and databases and logs data from each alarm server to an alarm history database. You can use the Alarm and Event Log Viewer to view and print data from alarm history databases. Third-party database tools can also retrieve, view, analyze, and print alarm history information.

To use alarm and event logging, install Microsoft® SQL Server separately, or use an existing Microsoft SQL Server database.

define alarm conditions; configure alarm servers; view and interact with alarm conditions; and view and run reports on historical alarm information.

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FactoryTalk Alarm and Event Features

As shown in Figure 5 on page 56, FactoryTalk Alarm and Event services have a complete set of visualization components (alarm summary, alarm log viewer, alarm banner, alarm status explorer).

Additional features include the following:

• Up to 10 alarm servers on the system; each server can be made redundant for fault tolerance

• Native ability to log alarm history to SQL database

• Ability to associate up to four additional tags with each alarm to store

additional process information with each alarm occurrence

• Ability to associate FactoryTalk View commands with alarms. For example, a command can be used to open the process display associated with the alarm from the Alarm and Event Summary or from the Alarm and Event Banner

• Language switching for alarm messages

• Logs alarm in UTC time

The alarm system does not support PanelView™ Plus terminals. But the Library of Process Objects supports mixed architectures (PanelView Plus terminals plus distributed HMI) while managing the alarm state in the controller. See page 59 for more on the Library.

FactoryTalk Alarm and Event Recommendations

• You can have up to 10 alarm servers in a PlantPAx system.

• The number of alarms per alarm server is limited to 20,000. This limit

could be affected when using handshaking with Process objects.

• Configure your alarms by using tag alarm and events on a server connected to Process Objects for alarm detection. This configuration provides integration with the displays and faceplates and makes sure of performance.

The Library of Process Objects contains Alarm Builder, which automates this configuration. See the Rockwell Automation® Library of Process Objects Reference Manual, publication PROCES-RM002 information.

• Use alarm groups on tag-based alarm and event servers to organize alarms by operator role.

• Use alarm expressions against user groups to provide rolled up indication of alarms by role or display. For example, AE_InAlmUnackCount('T1*') returns a count of unacknowledged alarms within groups that start with T1.

, for more

See the FactoryTalk View Site Edition User's Guide, publication VIEWSE-UM006,

for more information on

alarm expressions.

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Chapter 4 Alarm System Recommendations

• Use an alarm class to identify alarms that share common management requirements (for example, testing, training, monitoring, and audit requirements). Do not use alarm class to identif y alarms by operator role or display because you cannot retrieve an alarm count by class by using alarm expressions in FactoryTalk View software. However, you can filter by class on the alarm displays.

• Be aware that controller scan time and memory usage are variable with the use of the ALMA or ALMD instructions, depending on the states of the controller. Large alarm bursts can have a significant impact on controller CPU utilization.

For example: Controller memory used for buffering by each subscriber

(topic in the data server) = 100 KB

Example execution times:

– ALMD in a 1756-L73 controller with no alarm state changes: 7 μs – ALMD in a 1756-L73 controller with alarm state changes: 16 μs

In redundant controller configurations, crossloading of redundancy can add up to 70 μs per ALMD instruction.

• We recommend that you reserve the use of ALMA and ALMD instructions for the most critical alarms. Although there are no hard-coded limitations, we recommend limiting the number of instructions to the following:

– 250 per redundant controller – 2000 per simplex controller.

• We recommend that you limit the number of alarms to 1500 per

controller. Although there are no hard-coded limitations, you could experience longer recovery time during system restoration.

You can use the PSE for sizing the number of alarm instructions for a more accurate limit that is based on your specific configuration. Be sure to add for additional memory that is required to maintain the alarm subscription as it is not accounted for in the PSE memory calculations.

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Using the Library of Process Objects for Alarms

The Library of Process Objects uses a dedicated Add-On Instruction, named P_Alarm, for each alarm in each device for alarm detection and to provide an interface to the tag-based alarm. Documentation is provided with the Process Library to describe how to connect the Add-On Instruction instances with the Tag Alarm and Event Server.

Following this method, P_Alarm is responsible for managing state and providing status to process displays and faceplates. Each P_Alarm that is being used is linked to a digital alarm on the alarm server to provide status to alarm displays and alarm history.

Figure 6 - Alarms in PlantPAx Library

Alarm System Recommendations Chapter 4

The Library of Process Objects approach includes the following advantages:

• Integration of alarms into library objects (Add-On Instructions, global objects, and faceplates) for ease of engineering and deployment

• Supports mixed architectures (PanelView Plus terminals plus distributed HMI) while managing the alarm state in the controller

• Flexible alarm management techniques are built in into the P_Alarm instruction

When using the Library of Process Objects, both the controller and server maintain alarm information to provide status information where needed. For this reason, proper configuration is critical.

We provide tools to automate this configuration. See the Rockwell Automation Library of Process Objects Reference Manual, publication PROCES-RM002

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Alarm State Model

The alarm system provides three mechanisms to help prevent prolonged indications of an alarm in the alarm summary: Suppress, Shelve, and Disable.

The Shelve and Suppress states let you clear the alarm from the alarm summary or banner while you are resolving a known alarm. You do not continue to view the alarm information once the alarm is acknowledged.

The Shelve state has a configurable timeout, after which the alarm is automatically Unshelved and returned to the alarm summary. The Suppress state does not have an automatic timeout. If the alarm is unacknowledged at the time it is Shelved or Suppressed, it continues to appear on the alarm summary and banner until it has been acknowledged, and subsequently removed from these lists.

A Shelved or Suppressed alarm is still able to transition alarm status (except becoming unacknowledged), send alarm state changes to subscribers, log state changes in the historical database, and is responsive to other programmatic or operator interactions. Follow these rules:

• When an alarm is Suppressed or Shelved, it continues to function normally, monitor the In parameter for alarm conditions, and respond to Acknowledge requests. All subscribers are notified of this event, and any alarm messages generated while the alarm is in the Suppressed or Shelved state include the Suppressed or Shelved status. An alarm cannot become Unacknowledged while Shelved or Suppressed.

• When an alarm is Unsuppressed or Unshelved, all subscribers are notified and alarm messages to subscribers no longer include the Suppressed or Shelved status. If the alarm is active when Unsuppressed or Unshelved and Acknowledge is required, the alarm becomes Unacknowledged.

Disable an alarm to take the alarm out-of-service in the control program. A disabled alarm does not transition alarm status or gets logged in the historical database. If the alarm is unacknowledged at the time it is Disabled, it continues to appear on the alarm summary and banner until it has been acknowledged, and subsequently removed from view. A disabled alarm can be re-enabled in the Alarm Status Explorer in FactoryTalk View SE software:

• When an alarm is Disabled, all of its conditions are inactivated (InAlarm is cleared) except the acknowledged status if unacknowledged. The In parameter is not monitored for alarm conditions, but responds to an acknowledged event. All subscribers are notified of this event.

• When an alarm is Enabled, it begins to monitor the In parameter for alarm conditions. All subscribers are notified of this event. If the alarm is active when Enabled and acknowledge is required, the alarm becomes unacknowledged.

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Shelve, Suppress, and Disable states are all methods to suppress indication of alarms, following ANSI/ISA-18.2, Management of Alarm Systems for the Process Industries. You can use Shelve, Suppress, and Disable functionality to differentiate operator-initiated actions from design-initiated actions and maintenance actions. See the following examples and accompanying notes.

Operator Actions

Use the Shelve state to initiate this action by the operator (equivalent to the Shelve state in ISA 18.2).

The Program Unshelve command is provided so that the user has a means, by using a small amount of programming, to Unshelve alarms based on an event, for example End of Shift.

Program Actions

The controller must use the Suppress state to programmatically inhibit operator notification (equivalent to the Suppress-by- Design state in ISA 18.2).

The Suppress state is intended for Suppress-By-Design functionality under control of logic in accordance with ANSI/ISA-18.2. If logging of alarm transitions during suppression is not desired, use logic to suppress the input condition to the alarm. You also can use the P_Alarm Add-On Instruction in the Library of Process Objects, which does not generate new alarm transitions in the Suppress state.

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Maintenance Actions

Use the Disable state to inhibit the alarm for maintenance purposes (equivalent to Out-of-Service state in ISA 18.2).

The Disable state is intended for Out-of-Service functionality under control of maintenance in accordance with ANSI/ISA-18.2. If logging of alarm transitions during Disable is desired, the Suppress state of the ALMA or ALMD can be used instead if not required for Suppress-by-Design functionality under control of logic.

Alarm, Return to Normal, Latching, and Acknowledgement

While Disabled, Suppressed, or Shelved, an acknowledged alarm does not become unacknowledged.

While Disabled, Suppressed, or Shelved, if acknowledge is required, an unacknowledged alarm remains unacknowledged until it is acknowledged.

An alarm becomes unacknowledged if the alarm is InAlarm when an alarm changes state to Enabled, Unsuppressed, and Unshelved.

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Alarm System Recommendations Chapter 4

Monitoring Your Alarm System

By using the alarm status explorer, you can browse all of your configured alarms on a server or the entire system. Alarms also are filtered by the Shelved, Suppressed, and Disabled options. The alarm explorer can be preconfigured as a Shelved alarm display to let operators view a list of alarms.

ISA 18.2 provides alarm performance metrics and example target values that are summarized in a single table of section 16.9 of the standard. Some key metrics include the following:

1. Alarm rates: annunciated alarms per operator: a. < 150…300 alarms per day b. Average of 6…12 per hour c. Average 1…2 per 10 minutes

2. Contribution of the top 10 most frequent alarms to the overall alarm load: ~<1…5% maximum, with action plans to address deficiencies

3. Number of alarms that remain in effect continuously for more than 24 hours (stale alarms): Less than 5, with plans to address

When using the FactoryTalk® VantagePoint® software with the alarm system, reports are provided based on the described metrics.

1. Hourly Alarms Report (active count of alarms over 1- hour samples)

2. Alarm Distribution Report (percentage contribution of top 10 most

frequent alarms)

3. Alarm Frequency Report (top 10 most frequent alarms)

4. Standing Alarms Report (top 10 currently active alarms by duration)

5. Alarm Duration Report (top 10 alarms by duration)

Alarms can be filtered in FactoryTalk VantagePoint software by class, alarm name, or alarm source so they can be broken down by operator role if required. More information on these reports can be found on the Rockwell Automation Knowledgebase Answer ID 68296 at http://www.rockwellautomation.custhelp.com

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Notes:

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Chapter 5

Infrastructure Recommendations

This chapter describes best practices for infrastructure, including virtualized machines. We also include operating system and network recommendations.

Physical Access Control

We recommend implementing physical security to help protect your PlantPAx® system. Physical securities are measures that guard against unauthorized access to facilities, control rooms, equipment, and resources.

Consider policies and procedures to create layers of protection in their perimeter for authorized access to the system. The standards generally categorize these protections as the following:

• Passive physical security devices — This category includes physical controls such as fences, walls, concertina wire (barbed wire, razor wire, and so on). Physical controls also includes anti-vehicle ditches, concrete barriers, earthen walls or mounds, and other access limiting devices. Passive security devices are typically categorized as being of large size or mass, used to either protect physical entities or help prevent access to specific locations, and are active always. These devices require no manual intervention to either engage or disengage their security activities.

• Active physical security devices — These devices play an active role in physical security. These devices include doors, locks of various types, gates, retractable road obstructions, or other devices that are intentionally engaged or disengaged based on either time intervals, autonomous control, or at specific intervention from an outside source. These devices are often coupled with additional identification or monitoring devices to enhance their functionality.

• Identification and monitoring devices — This category includes still and video cameras, motion sensors, vibration sensors, heat sensors, biometric authentication or recording devices, and various other devices. They do not by themselves specifically control or limit access to a physical location or system. The design and intended use of these devices are specific to detecting, identifying, or recording physical entities. These devices include the state of physical presence of individuals, vehicles, systems, or other identifiable physical objects.

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Infrastructure Types

The PlantPAx system infrastructure is built on an IT infrastructure based on the following:

• Commercial off-the-shelf technologies, such as Microsoft Windows and VMware

• Open network technologies, such as Stratix® switches

The platform provides seamless integration between system elements and higher-level business systems.

When building your system, you must decide whether your server and client workstations are in a virtual or traditional environment.

Traditional

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.

Virtual

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.

Before designing a virtualized PlantPAx system, we recommend that you have a general understanding of the PlantPAx control system architectures and sizing guidelines.

For more information, see the following:

• PlantPAx Distributed Control System Selection Guide, publication PROCES-SG001

-- Provides descriptions of system elements,

architectures, and sizing guidelines for procuring a virtual PlantPAx system

• PlantPAx Virtualization User Manual, publication 9528-UM001

Contains step-by-step procedures for configuring virtual machines

The following table lists where to find specific information.

Top ic Pag e

Virtual PlantPAx Configuration Recommendations 67

Operating System Recommendations 72

Network Recommendations 75

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Virtual PlantPAx Configuration Recommendations

Once the basic architecture is developed, a virtualized PlantPAx system benefits from a number of fundamental VMware configuration choices. Most of these choices start with automatic settings, with adjustments made as required to increase speed and improve redundancy.

The PlantPAx system does not require the use of the virtual image templates, nor does their use infer the system design meets PlantPAx system specifications. Use of the virtual image templates can save time and make sure consistency of installation with the recommendations contained within this manual.

Servers

The latest Intel™ processors offer onboard virtualization support. The Intel Virtualization Technology in the BIOS must be switched on to take advantage of the performance gains.

Hosts in the same cluster that have different processors are recommended to have Enhanced vMotion Compatibility (EVC) enabled to support the vMotion between hosts. EVC is enabled at the Datacenter/Cluster level. EVC is a fundamental technology that facilitates virtual machine modernization between different generations of CPUs, while vMotion is the utility used to make the modernization. The ability to modernize VMs between servers while they are running with the process transparent to any users is one of the leading benefits of virtualization.

Keep VMware Tools up-to-date inside each guest operating system. When modernizing or converting a VM from an older version ESXI server, a best practice is to remove the old Tools and install the latest version.

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IMPORTANT

Storage

Network attached storage uses a software network adapter to connect with iSCSI storage through Ethernet. Enable jumbo frames at the physical switch level and also at the virtual switch port level. Jumbo Ethernet frames carry up to 9000 bytes of payload (as opposed to the normal 1500) and can offer increased data throughput with reduced CPU utilization. The network must be configured to support jumbo frames from end to end.

When configuring the physical NICs on a host, set up NIC teaming in the virtual switch configuration to enable greater bandwidth for storage traffic.

Each virtual hard disk drive on a network is assigned a logical unit number (LUN) for unique identification. A LUN is a logical unit number of a virtual partition in a storage array. When assigning virtual hard disk drives from VMs to a LUN, be sure to balance intensive and non-intensive I/O applications. This process improves performance by balancing I/O traffic across multiple hard disk drives. A typical LUN size is 400...800 GB. The maximum number of virtual machine hard disks (VMDK) on a LUN cannot exceed 30, as more VMDKs could impact the performance because of disk queuing.

The LUN size is calculated by adding the total capacity (GB) of storage required plus VM Swap File requirements and additional room for VM Snapshots. When dividing the storage array into LUNs, the following equation can be used to determine appropriate sizing.

Calculated LUN Size = GB Capacity + VM Swap File Requirements + Snapshot Reservations

= 30*(average VM virtual disk size) + 30*(average VM RAM) + 15% of (30 x average disk size).

Virtual Networks

Connect VMs that are on the same ESXi server and same VLAN to use the same virtual switch. If separate virtual switches are used and connected to separate physical NICs, traffic routes separately through the wire and incur unnecessary CPU and network overhead.

Speed and duplex settings mismatches are common issues that can cause network problems. For ESXi, VMware recommends autonegotiate for both devices on the ends of a network link. It is also acceptable to set both ends for ‘1000 MB/fullduplex’ or ‘100MB/full-duplex’ if required by the network hardware.

If you connect a manually configured device to an autonegotiate device (duplex mismatch), a high rate of transmission errors can occur.

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VMware systems demand a high level of network performance by nature, so methods to reduce bottlenecks are to be explored. One such method is NIC teaming, where a single virtual switch can be connected to multiple physical Ethernet adapters. A team that is defined in this way can share the traffic load and provide a means of failover.

There are several options available for load balancing. The default is ‘route based on the originating virtual switch port ID’, where traffic from a given virtual Ethernet adapter is consistently sent to one physical adapter (unless there is a failover). Another option gives the virtual switch the ability to load balance between multiple physical adapters. This is set by configuring EtherChannel link aggregation on the Cisco® switch and the load balancing setting is set to ‘route based on IP hash’ in the virtual switch.

A combination of NIC teaming and the Cisco Switch load-balancing settings are recommended for improved performance when you access networked storage.

Resource Pool Allocation

Resource pools group virtual machines (VMs) to provide dynamic allocation of CPU and memory resources. Resource pools also contain child resource pools that enable fine-grained resource allocation.

Resource allocation is done on an individual VM basis by using shares, reservations, and limits. Setting these values on every VM is time-consuming, can be error-prone, and doesn't scale effectively. Setting these values on a resource pool is much more efficient, and the values dynamically readjust as VMs and host resources are added and removed.

Generally, the hypervisor provides excellent scheduling. And, if hosts have sufficient resources, you can leave the default settings alone. If you wish to control the VMs that receive more priority or resources, it's more effective and less error-prone to allocate the VMs at a resource pool level.

In a PlantPAx system, make sure that the PASS servers and workstations have higher priority for consistent performance.

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For each resource pool, you set CPU and memory shares, reservations, expandable reservations, and limits, as shown in Figure 7

Figure 7 - Setting Resource Pool Allocation

We recommend that you build three resource pools with the server-type allotment that is shown in Ta b l e 3 4

Table 34 - Server Resource Pool Allocation

Resource Pool Name CPU Shares CPU Reser vation Memory Shares Memory Reservation Server or Workstation

High High 50% of available host CPU Hz High Minimum as specified for each

Normal Normal Zero Normal Zero EWS

Low Low Zero Low Zero FactoryTalk® Direc tory

virtual template

PAS S OWS AppServ-OWS

AppServ-EWS AppServ-Asset AppServ-Batch AppServ-Info

Domain Controller

An allocation of zero means that no resources get locked from being used by the hypervisor resource allocation algorithm. The Expandable and Unlimited boxes need to be checked.

The CPU or memory shares are relative to any sibling resource pools or VMs. Shares are used only during periods of contention and are always bound first by any reservations or limits. In a well-designed PlantPAx system, sufficient resources are available to all VMs in the resource pool, therefore, we suggest that shares never be invoked. They are built to make sure that the PASS and workstations can consistently supply data if there is contention.

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Resource Pool Sizing Example

This example shows how to allocate resources based on system requirements.

System:

• 1 server with 2 quad-core CPUs (each core is 2.0 GHz)

• 32 GB of RAM

• Server has a total of 16 GHz of CPU to allocate to virtual machines

PlantPAx system:

• 4 PASS servers and 1AppServ-OWS — High resource pool

• 1 AppServ-Hist, 1 EWS, and 1 AppServ-Asset — Normal resource pool

• 1 FactoryTalk Directory and 1 domain controller — Low resource pool

Following the guidelines above, the High resource pool with get 50% of the CPU allocated, or 8 GHz. These 8 GHz are further divided into 5 shares of 20% automatically for each server in the resource pool. Each server receives roughly

1.6 GHz (8 GHz/5 servers) of CPU minimum allocation. The minimum memory for each server used in the High resource pool is 4 GB. Minimum memory allocated is 20 GB (4 GB x 5 servers).

The remaining 8 GHz CPU and 12 GB of RAM is used by the hypervisor resource allocation algorithm to use where needed. The Normal resource pool has priority over the Low resource pool, but there is no minimum resource allocation due to the zeroes used for CPU and memory reservation.

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TIP

IMPORTANT

Operating System Recommendations

The following recommendations apply regardless if you are using a virtual or traditional environment and the size or complexity of the system operation.

Domains and Workgroups

We recommend that PlantPAx servers and workstations be members of a Windows domain. However, workgroups are supported for systems with 10 or fewer workstations and servers.

Configuration Details

Workgroup - decentralized administration

(allowed if 10 or fewer computers)

Domain - centralized administration

(recommended)

Workgroup advantages:

• No domain controller (Windows Server OS) to purchase or maintain.

• Recommended for small PlantPAx applications only where user accounts do not change often

Workgr oup r ules :

• Workstation and server system elements in a single PlantPAx system must be members of the same workgroup

• Users that participate in the workgroup must be members of the Administrators group

• Create the same set of user accounts and passwords on every computer in a FactoryTalk View application

Domain advantages:

• One place to manage users, groups, and security settings

• Recommended for larger PlantPAx applications, or environments with changing user accounts

Domain rules:

• All workstation and server system elements in a single PlantPAx system must be members of the same domain

• PlantPAx server system elements must not be used as domain controllers.

• Required for systems with more than 10 computers

• The domain controller must be its own independent computer with no other application software.

Domain Recommendations

We recommend that all PlantPAx system servers and workstations be a member of a domain. Follow these additional recommendations:

• Windows Active Directory (AD) domains include the concept of a ‘forest’ that can consist of a single ‘domain tree’ or multiple domain trees.

A domain tree can consist of a single (parent) domain or multiple (child) domains. In a Windows 2016 Active Directory, both domains and forests have individual functional levels.

• We recommend configuring at least two domain controllers in the domain. These domain controllers replicate automatically to provide high availability and an online configuration backup. If you have a single domain controller, and it goes offline, your system goes offline.

• The domain servers also must be configured to include Domain Name Service (DNS) that lets you identify devices by name rather than IP addresses.

• Configure time synchronization throughout a domain.

Do not install the Windows domain controller on the PlantPAx PASS server or application servers. For more information, see the PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001

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Windows Workgroup Recommendations

The PlantPAx system can use a Windows workgroup network environment for systems with 10 or fewer computers.

For more information, see the Appendix section in the PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001

Server and Workstation Time Synchronization

System time synchronization is important so that the internal clocks in the controllers, workstations, and servers reference the same time for any event or alarm that occurs. Configure the PASS, App-servers, OWS, and EWS to use a single server (for example, a domain controller) as their time reference and keep their clocks tightly synched to it.

Computer Time Synchronization

The Windows Time service uses the network time protocol (NTP) to synchronize computer clocks on the network from the domain controller. Each computer in the process system uses the domain controller as the authoritative time source and synchronizes their clock to it. Check the Event Viewer System log of each computer to verify that the time is updated properly.

After configuring the domain controller for time synchronization, you can use the Windows w32tm command-line tool to identify any time difference between an individual computer and the domain controller. This command measures the time difference.

w32tm /stripchart /computer:<target>[/period:<refresh>] [/dataonly]

Parameter Identifies

computer:<target> The computer to measure the offset against.

period:<refresh> The time between samples, in seconds. The default is 2 s.

dataonly To display the data only without graphics.

The w32tm/resync

command manually forces a computer to resynchronize its

clock to the domain controller as soon as possible and resets error statistics.

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Operating System Optimization

The following recommendations enhance the performance of your operating system:

• Turn off Windows automatic updates to help prevent compatibility issues with existing PlantPAx components on your workstations.

See Maintenance Recommendations apply Microsoft patches to your PlantPAx system.

• Disable operating system themes that provide personalized computer effects such as sounds and icons. These types of elements diminish processor speed when running some FactoryTalk View SE graphic components, such as alarm summaries.

• Disable or uninstall all third-party firewalls on a workstation before installing FactoryTalk View SE software, which is compatible only with the built-in Windows operating system firewall.

• Remove Enhanced Security Configuration (ESC) from workstations running FactoryTalk View SE software. The Windows 2016 security settings help protect servers by limiting how users can browse the Internet on a computer, but can hinder FactoryTalk clients connecting to application servers.

for more information on how to

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Network Recommendations

The Ethernet network provides the communication backbone for the supervisory network for the workstations, servers, and the controllers:

• Configure all communication interfaces to operate at the fastest speed possible for your hardware configuration, full-duplex for 100/1000 network adapters. See Important for autonegotiate settings.

Use of autonegotiate settings is recommended to reduce chance of mis-configuration and failures. However, it is desirable to operate at the fastest speed possible at full-duplex. We recommend verifying your switch settings during commissioning to make sure that the system was able to autonegotiate properly. The speed and duplex settings for the devices on the same Ethernet network must be the same to avoid transmission errors.

• Disable power saving for the Network Interface Card (NIC) that connects a workstation to other devices on the network. The power-saving feature turns off the network card when not in use, which can interfere with network throughput.

• If multiple DCOM protocols are installed and set up on a workstation, to make sure that DCOM communication functions correctly, remove all protocols other than TCP/IP.

For procedures, see the PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001

• Consider cable type for environmental conditions.

Type De tails

Fiber-o ptic • Long distan ces

Shielded twisted-pair • Use Category 5e, 6, or 6a cables and connectors

• Near high magnetic fields, such as induction-heating processes

• For extreme high-noise environments

• For poorly grounded systems

• For outdoor applications

• Use termination sequence 568A for industrial applications

See the following publications for additional information:

• For step-by-step configuration instructions, see the PlantPAx Distributed Control System Infrastructure Configuration User Manual, publication PROCES-UM001.

• For correcting a duplex mismatch, see Troubleshoot EtherNet/IP® Networks, publication ENET-AT003

• For fiber cable specifications and an example of dB loss, see Appendix C in the EtherNet/IP Modules Installation Instructions, publication ENET-IN002

• For selecting architecture, see the Ethernet Design Considerations Reference Manual, publication ENET-RM002, Guide, publication PROCES-SG001

or the PlantPAx Selection

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Ethernet Switches

The supervisory network must have managed switches that direct specific messages to multicast groups. Do not use unmanaged switches. The behavior of an unmanaged switch is to flood multicast packets to all ports within the same VLAN.

The first switch that Rockwell Automation equipment touches must have IGMP snooping enabled. IGMP snooping enables switches to forward multicast packets to ports that are only part of a particular multicast group.

All applications require proper configuration to achieve the best system performance. If you do not configure the managed switch, it’s possible that system performance can be adversely affected. We recommend that you contact your system administrator if there are any doubts on the installation and configuration.

Select the switch depending on the network functionality.

If Then

• Supervisory

• Routing information to other networks

• Connecting control hardware, sensors, and workstations

• Isolated networks

High availability at switch level Layer 3 switch

Layer 3 switches

• Stratix 5410

• Stratix 5400

Layer 2 switches

• Stratix 5410

• Stratix 5400

• Stratix 5700

• Stratix 5410

(1)

(1) For uplink cables between Layer 2-3, fiber is recommended for better system performance.

Additional Switch Information

See the Stratix Ethernet Device Specifications Technical Data, publication 1783-TD001

• Stratix 5900 Security Appliance

• Embedded EtherNet/IP Taps

We also support the use of Cisco switches. To help make sure of performance, we recommend that all system switches are Cisco or Stratix for common use of protocols.

The following switches are also supported on the PlantPAx system:

• Cisco Catalyst® 3850 (Layer 3)

• Cisco Catalyst 4500x (Layer 3)

• Cisco Catalyst 2960G (Layer 2)

• Cisco Catalyst 9300 (Layer 3)

, for information on these switch components:

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Chapter 6

Field Device Integration Recommendations

Modern field devices, such as drives and flow transmitters, are often microprocessor-based. These smart devices provide digital data that is used for commissioning, maintenance, troubleshooting, and most importantly, control.

Smart field devices use two-way, digital protocols for communication. Common field device communication options on the PlantPAx® system include EtherNet/IP™, ControlNet®, DeviceNet®, FOUNDATION Fieldbus, PROFIBUS PA networks or by using HART.

This section provides general recommendations for how to configure tools on the networks and HART protocol. The tools help gather real-time information and diagnostics to make well-informed business decisions.

Additionally, many other networks and I/O protocols can be integrated into the PlantPAx system. For more information on Encompass™ third-party products, see

http://www.rockwellautomation.com/encompass

The following table lists where to find specific information.

Top ic Pag e

Device Configuration Options 78

EtherNet/IP Recommendations 78

ControlNet Recommendations 80

DeviceNet Recommendations 81

HART Recommendations 82

FOUNDATION Fieldbus Recommendations 83

PROFIBUS PA Recommendations 85

Motor Control Recommendations 87

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Device Configuration Options

There are several options to configure field devices:

• Handheld devices for selected field device networks or protocols

• Manually configure some instruments by using the local interface

• Enterprise-wide solution by using FactoryTalk® AssetCentre

FactoryTalk AssetCentre for Enterprise Solution

FactoryTalk AssetCentre software can be used as a centralized tool to manage field devices from multiple vendors, networks, and protocols from one common platform. FactoryTalk AssetCentre software leverages FDT technology that standardizes the communication interface between field devices and host systems. This functionality accesses any device from FactoryTalk AssetCentre software regardless of the communication method.

The FDT interface also enables FactoryTalk AssetCentre software to integrate many different kinds of devices, including handheld diagnostic tools.

For more information, see the following publications:

• FactoryTalk AssetCentre Product Profile, publication FTALK-PP001

• FDT website at http://www.fdtgroup.org

EtherNet/IP Recommendations

The EtherNet/IP protocol is a multi-discipline, control, and information platform for use in industrial environments and time-critical applications. EtherNet/IP uses standard Ethernet and TCP/IP technologies and an open, application layer protocol that is called the Common Industrial Protocol (CIP).

A growing number of field devices, including flow transmitters and drives, are available that support EtherNet/IP.

Table 29 - EtherNet/IP Interfaces

Category Product Description

ControlLogix® controller interface 1756-EN2T, 1756-EN2TR,1756-EN3TR,

1756-EN2F 1756-ENBT

1788-EN2FFR EtherNet/IP to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION

1788-EN2PAR EtherNet/IP to PROFIBUS PA linking device. Supports PA media. Compatible with

ControlLogix EtherNet/IP bridge.

Fieldbus network. Compatible with ControlLogix redundancy. Built-in functionality for the Ethernet DLR.

ControlLogix redundancy. Built-in functionality for the Ethernet DLR.

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IMPORTANT

EtherNet/IP I/O Communication Options

Follow these guidelines for EtherNet/IP networks:

Network

• Configure all communication interfaces to operate at the fastest speed possible for your hardware configuration, full-duplex for 100/1000 network adapters. See the Important for autonegotiate settings.

• When expanding the I/O configuration tree, make sure your I/O module RPI is two times faster than the periodic task that you are using.

• As you expand the I/O configuration tree, devices can affect the CIP/TCP count differently. Never use more than 80% of the available connections for the bridge modules.

• I/O packets per second (pps) describes an implicit message rate (Class 1). An I/O Comms Utilization value approaching or above 80% can necessitate an adjustment to the RPI.

• HMI packets per second (pps) describes an explicit message rate (Class 3). FactoryTalk Linx connections and message instructions generate CIP traffic. HMI traffic is TCP-based, not UDP-based.

• The combination of implicit and explicit messaging provides a total utilization for a device. If you add implicit messaging (I/O), it takes bandwidth from the HMI because it has higher priority than HMI messaging. The combination of CIP implicit (highest priority) and CIP explicit (second priority) cannot exceed 100% use.

Devices

• Consider packets per second (see network notes) for performance if you use many devices.

• Use compatible keying on Ethernet communication modules. In a validated environment, you can use an exact match for keying.

See the documentation that is listed in Additional Resources more information.

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ControlNet Recommendations

The ControlNet network is an open, control network that combines the functionality of an I/O network and a peer-to-peer network, providing high-speed performance for both functions.

ControlNet I/O Communication Options

In a PlantPAx system, the ControlNet network supports controller downlinks and connections to remote I/O and field device interfaces. The network is unaffected when devices are connected or disconnected from the network.

Table 35 - ControlNet Interface

Category Product Description

ControlLogix controller interface 1756-CN2, 1756-CN2R

1756-CNB, 1756-CNBR

1788-CN2FFR ControlNet to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION

1788-CN2PAR ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media

Follow these guidelines for ControlNet networks:

Control Logix ControlNet sc anner.

Fieldbus networks. Compatible with ControlLogix redundancy and redundant ControlNet media.

and redundant ControlNet media. Compatibl e with ControlLogix redu ndancy.

Network

• When you configure the ControlNet network with RSNetWorx™ for ControlNet software, select Optimize and rewrite the schedule for all connections.

If changes are made to the ControlNet configuration, upload the configuration to make sure that it gets backed up to the Studio 5000 Logix Designer® project.

• Use a maximum of five controllers with a rack-optimized, listen-only connection to the module.

• Use a maximum of 64 I/O modules on an unscheduled remote I/O ControlNet network.

• Use a maximum of 20 ControlNet interface modules per controller.

Devices

• A ControlNet node can transmit 480 bytes of scheduled data in a single network update time (NUT).

• I/O modules on ControlNet can be unscheduled to allow adding I/O online.

• Do not leave any ControlNet node addressed 99 (default address on some new devices).

See the documentation listed in Additional Resources more information.

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DeviceNet Recommendations

The DeviceNet network is an open, device-level network that provides connections between simple industrial devices (such as sensors and actuators) and higher-level devices (such as PLC controllers and computers).

DeviceNet Communication Options

In a PlantPAx system, the DeviceNet network connects networked control devices.

Table 36 - DeviceNet Interface

Category Product Description

ControlLogix controller interface 1756-DNB ControlLogix DeviceNet scanner.

Follow these guidelines for DeviceNet networks:

Network

• Connect up to 48 devices to the scanner when an average amount of data input and outputs is used.

• Use a maximum of 80% of the available scanner input and output memory.

• If you use more input and output device data, we recommend that you

reduce the number of devices. For example, an MCC device, such as a soft starter, with all the available data enabled can use up to 40 bytes for input and 40 bytes for output. In this scenario, the maximum devices that we recommend connecting to the scanner is 10.

• To make sure that the network is within limits, calculate the amount of input and output memory that the scanner needs.

• We recommend disabling Auto Address Recovery. If enabled, in some scenarios like a power outage, two devices can auto-recover to the same address.

• Store EDS files in a common location; install on engineering workstations.

Scanner

• Keep DeviceNet communication modules in the local chassis. If the communication module is in a remote chassis, set the input and output sizes to match the data configured in RSNetWorx for DeviceNet software.

• Never have any device set to the default node address of 62 (reserved for personal computer) or 63 (reserved for new device to be configured).

• Set the scanner address to node 0.

• Keep the Interscan Delay  5 ms.

• Set DeviceNet scanner RPI time to half the scan rate of the fastest task in

the controller that uses the DeviceNet network, but not less than 2 ms.

• Use Background poll when possible. Keep (Foreground to Background Poll Ratio) * (Interscan Delay) > 75 ms.

See the documentation listed in Additional Resources more information.

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HART Recommendations

HART is an open protocol designed to provide digital data over 4…20 mA analog signals.

HART Communication Options

The PlantPAx system interfaces both directly and via remote I/O modules to provide a single termination point to gather analog process variables and the additional HART digital data.

Table 37 - HART Interface

Category Cat. No. Description

Chassis-based I/O modules 1756-IF8IH, 1756-IF16H, 1756-OF8H, 1756-OF8IH ControlLogix analog isolated I/O modules. These modules provide basic configuration

Distributed I/O, high-channel density 1794-IE8H, 1794-OE8H,

1794-IF8IH, 1794-OF8IH, 1794-IF8IHNFXT

Distributed I/O, low-channel density 1734-sc-OE2CIH, 1734-sc-IF4H Spec trum Controls, analog input module with HART for the POINT I/O™ system.

1769-sc-IF4IH, 1769-sc-OF4IH Spectrum Controls, analog, isolated input and output modules with HART

Distributed I/O, intrinsically safe 1719 Ex I/O Rockwell Automation, chassis-based design for Zone 2 or Class I, Div 2., via EtherNet/IP.

Multiplexers/gateways N/A See the Encompass website for Pepperl+Fuchs, ProSoft Technology, and Aparian

Network configuration Handheld device Endress+Hauser

through the I/O tree, provide status and diagnostics information, and provide remote configuration and troubleshooting.

FLEX analog I/O modules with the following:

• Standard profiles in Studio 5000 Logix Designer

• DTM s

for Compact I/O™ modules.

product offerings.

(1)

, handheld configuration and diagnostic device.

See the Encompass website for Endress+Hauser product offerings.

(1)

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

Follow these guidelines for connectivity to a HART I/O card:

Network

• For 8-channel HART cards, only enable HART data on the channels that are connected to HART devices and you want to receive HART data. Enabling unused channels reduces system resources and performance.

• For 16-channel HART cards, there is no decrease in system performance by enabling all channels.

Devices

• If using HART data for control, check the data quality bits.

• For controlling fast loops, use only the 4...20 mA output of the instrument

for control instead of the extended HART data.

For more information, see the following resources:

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

• Documentation listed in Additional Resources on page 8

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FOUNDATION Fieldbus Recommendations

The FOUNDATION Fieldbus network is a digital, two-way, multi-drop communication link among multiple intelligent field devices and automation systems.

FOUNDATION Fieldbus Communication Options

The PlantPAx system communicates with FOUNDATION Fieldbus devices through EtherNet/IP and ControlNet linking devices.

Table 38 - FOUNDATION Fieldbus Interface

Category Cat. No. Description

EtherNet/IP interface 1788-EN2FFR EtherNet/IP to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION

Fieldbus network. Compatible with ControlLogix redundancy. Built-in functionality for the Ethernet DLR.

ControlNet interface 1788-CN2FFR ControlNet to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION

Fieldbus networks. Compatible with ControlLogix redundancy and redundant ControlNet media.

FOUNDATION Fieldbus network components

Power conditioning Both linking devices have built-in power conditioning.

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

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

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

barrier systems, hazardous area enclosures, and equipment. See the Encompass website for Pepperl+Fuchs product

offerings.

(1)

, FOUNDATION Fieldbus components, such

(1)

, intrinsic safety components, such as isolated

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

Follow these guidelines for FOUNDATION Fieldbus networks:

Simplex Controllers

• We recommend a maximum of 32 fieldbus segments.

• Use 8…12 devices per segment.

• Use only two terminators per bus segment to help prevent distortion and

signal loss. Some linking devices have built-in terminators but typically terminators are placed at the ends of the trunk.

Redundant Controllers

• We recommend a maximum of 16 fieldbus segments.

• Use 8…12 devices per segment.

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Chapter 6 Field Device Integration Recommendations

IMPORTANT

• Use only two terminators per bus segment to help prevent distortion and signal loss. Terminators are placed at the ends of the trunk.

Each linking device, whether configured with a simplex or redundant controller, can support one H1 segment.

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Field Device Integration Recommendations Chapter 6

Network

• To make sure that the fieldbus network is within limits, add up your field device connections per segment to estimate controller I/O memory.

• Ground the network cable only to the distribution side. Do not connect either conductor of the linking device to ground to help prevent communication loss.

• Amount of load and voltage drop determine maximum cable length. For example, the more field devices and junction boxes added to the cable increases the load, which increases signal attenuation. Likewise, the bigger the load and longer the cable, the bigger the voltage drop.

• The voltage specification for the H1 segment is 9…32V DC. We recommend that you use a 24V DC, 1 A Fieldbus Foundation power supply and be sure to keep the voltage above 13V DC at the farthest end of the segment.

• Signal quality can be adversely affected by placing the cable near motors, high-voltage, or high-current cables.

• The update time (macrocycle) for the H1 network is determined by the bandwidth that each device fills. This data is provided in the device’s DD files.

Devices

• The linking device is a direct link between field devices on a Logix platform and the EtherNet/IP or ControlNet networks.

• Each linking device in the scanner uses four CIP connections in the controller.

• Built-in power conditioners reduce installation space requirements and open- and short-circuit protection guards against line faults.

• The Studio 5000® Add-on Profile (AOP) and graphical user-interface provides for online device configuration. New devices are automatically shown in the Live List.

• Add-on Profile (AOP) diagnostics that include an onboard oscilloscope report linking device and network statistics, such as noise and signal level and bad termination.

• Multiple levels of device and media redundancy are supported, including ring and dual trunk.

See the documentation listed in Additional Resources more information.

on page 8 for

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Chapter 6 Field Device Integration Recommendations

PROFIBUS PA Recommendations

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

PROFIBUS PA Communication Options

The PlantPAx system communicates with PROFIBUS PA devices through EtherNet/IP and ControlNet linking devices.

Table 39 - PROFIBUS PA Interface

Category Cat. No. Description

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

1788-CN2PAR ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media

PROFIBUS network components Power conditioning Both linking devices have built-in power conditioning.

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

1788-FBJB6 Intelligent junction box with six drop ports.

Additional components Pepperl+Fuchs

Segment protection Helps protect against device or line faults with short- and open-circuit protection.

and redundant ControlNet media. Compatibl e with ControlLogix redu ndancy. Built-in functionality for the Ethernet DLR.

and redundant ControlNet media. Compatibl e with ControlLogix redu ndancy.

(1)

, FOUNDATION Fieldbus components, such as valve couplers, surge

protectors, and distributors. See the Encompass website for Pepperl+Fuchs product offerings.

Pepp erl+Fu chs hazardous area enclosures, and equipment.

See the Encompass website for Pepperl+Fuchs product offerings.

(1)

, intrinsic safety components, such as isolated barrier systems,

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

Follow these guidelines for PROFIBUS PA networks:

Simplex Controllers

• We recommend a maximum of 32 PROFIBUS segments.

• Use 15…20 devices per segment.

Redundant Controllers

• We recommend a maximum of 16 PROFIBUS segments.

• The PROFIBUS PA segment is split between two physical ports. Use

up to 10 devices per port.

Network

• PROFIBUS PA is a master-slave network.

• To make sure that the PROFIBUS network is within limits, add up your

field device connections per segment to estimate controller I/O memory.

• Ground the network cable only to the distribution side. Do not connect either conductor of the linking device to ground to help prevent communication loss.

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Field Device Integration Recommendations Chapter 6

• Amount of load and voltage drop determines maximum cable length. For example, the more field devices and junction boxes added to the cable increases the load, which increases signal attenuation. Likewise, the bigger the load and longer the cable, the bigger the voltage drop.

• The voltage specification for the PROFIBUS PA segment is 9…32V DC. We recommend that you use a 24V DC PA power supply and make sure to keep the voltage above 13V DC at the farthest end of the segment.

• Signal quality can be adversely affected by placing the cable near motors, high-voltage, or high-current cables.

Devices

• The linking device is a direct link between PROFIBUS PA devices and the EtherNet/IP or ControlNet networks, with no intermediate PROFIBUS DP (decentralized peripherals) layer required.

• Each linking device in the scanner uses four CIP connections in the controller.

• Built-in power conditioners reduce installation space requirements and open- and short-circuit protection guards against line faults.

• The Studio 5000 Add-on Profile (AOP) and graphical user-interface provides for online device configuration. New devices are automatically shown in the Live List.

• Add-on Profile (AOP) diagnostics that include an onboard oscilloscope report linking device and network statistics, such as noise and signal level and bad termination.

• Multiple levels of device and media redundancy are supported, including ring and dual trunk.

See the documentation listed in Additional Resources more information.

on page 8 for

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Chapter 6 Field Device Integration Recommendations

Motor Control Recommendations

Rockwell Automation offers two low-voltage motor control centers (MCC) that integrate control and power in one centralized location. The CENTERLINE® 2100 or CENTERLINE® 2500 MCCs can house starters, soft-starters, and drives to meet IEC, UL, and NEMA standards.

Devices

• Each MCC EtherNet/IP device consumes one TCP and CIP connection. Using the 1756-EN2TR module, the maximum connections supported are 256 CIP connections and 128 TCP connections.

• Following the 1756-EN2TR module guidelines, we cannot exceed 80% of the maximum connections. Therefore, it’s not recommended to use more than 100 MCC EtherNet/IP devices in a single 1756-EN2TR bridge module.

If it is necessary to use more than 100 MCC EtherNet/IP devices, it is recommended to add one more 1756-EN2TR bridge module. The additional module splits the communication and helps balance the bridges’ load.

• It is not recommended to use more than 150 devices in a single Simplex controller. Considering this limit, the expected CPU load is almost in recommended limits. In this scenario, we are using only the MCC EtherNet/IP components with the Rockwell Automation Library of Process Objects.

But, in a typical application, it is necessary to have other devices and objects in the same controller. This scenario means that there is a possibility that you cannot achieve the maximum 150 EtherNet/IP MCC components. It depends on your specific application. The PSE helps to determine these loads.

• Another important consideration is to use an adequate requested packet interval (RPI) to each device. We recommend that the RPI is half-speed of the task that is using the device. The default RPI timing can sometimes overuse the communication resources.

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Notes:

Field Device Integration Recommendations Chapter 6

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Chapter 7

Batch Management and Control Recommendations

PlantPAx® batch management and control include two options for a scalable solution:

• Controller-based single unit or multiple independent unit solutions, called Logix Batch and Sequence Manager (LBSM)

• AppServ-Batch for a comprehensive batch solution (FactoryTalk® Batch)

LBSM is the controller-based solution consisting of controller code and visualization elements for use on Logix5000™ and FactoryTalk View software.

See the PlantPAx Selection Guide

http://www.rockwellautomation.custhelp.com

AppServ-Batch uses FactoryTalk Batch software for a comprehensive, server-based solution that leverages Logix functionality (PhaseManager™). This chapter provides basic setup information for a comprehensive batch solution by using FactoryTalk Batch software.

The following table lists where to find specific information.

Top ic Pag e

FactoryTalk Batch Critical System Attributes 90

Batch Guidelines for Logix 90

Using a Redundant System with a FactoryTalk Batch Server 91

and Knowledgebase Answer ID 62366 at

for more information on LBSM.

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Chapter 7 Batch Management and Control Recommendations

FactoryTalk Batch Critical System Attributes

Table 40 - FactoryTalk Batch CSA

Batch Critical System Attribute Performance

Batch server: operator action time An operator batch command has been acted on by the controller in 1 second.

Batch server: server action time A server batch command has been acted on by the controller in 1 second.

Batch server: controller action time Batch status events display on the operator workstation within 1 second.

Batch Guidelines for Logix

The following critical system attributes (CSA) were used to verify performance for FactoryTalk Batch during process system characterization.

Phases can be developed by using PhaseManager to provide maximum modularity and reusability.

• In each phase, the running routine can track what step it is executing by using a step index variable (part of the equipment phase user-defined structure).

• If you are using sequencer logic (SFC) for state logic programming, the restarting state routine must reset the running SFC back to a specific sequence step, based on the step the running SFC was in when the phase received the Hold command. The function also depends on what actions the Holding state routine took with the equipment controlled.

• A Prestate routine is a state that can be added to each phase and always evaluated. The Prestate routine can be used to keep active or enable functionality (for example, a phase that runs an agitator that does not stop when Held, but you must keep track of the time the agitator ran).

• For SFC, any conditional code that is required for transitions (such as a transition to the next step on a timer done) can be implemented by using separately defined phase tags as opposed to step tag attributes. This task helps to prevent errors when copying sequencer logic.

• For more information, see these resources:

• PhaseManager User Manual, publication LOGIX-UM001 – Instructions on how to configure and use a Logix5000 controller with

equipment phases.

• Factory Talk Batch PhaseManager Users Guide, publication BATCH-UM011

– Specifics on how to use PhaseManager with FactoryTalk Batch

software.

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Batch Management and Control Recommendations Chapter 7

Logix 556x

Logix 556x Logix 556x

% .  4

,  

 2

% .  4

# .  2

% .  4

,  

FactoryTalk Batch Server Workstation or HMI

EtherNet/IP Network

Primary ControlLogix® Chassis Secondary ControlLogix Chassis

Fiber-optic Cable

ControlNet Redundant Module

To Remote I/O

EtherNet/IP Network

46286

Using a Redundant System with a FactoryTalk Batch Server

If your system requirements include the batch not going to hold on a controller switchover, you need to use both a ControlNet® bridge module and an EtherNet/IP™ bridge module to connect to the FactoryTalk Batch server. If batch hold upon controller switchover is acceptable, you can connect to the FactoryTalk Batch server directly from an EtherNet/IP module placed in the redundant chassis.

This illustration demonstrates one method of bridging the ControlNet network of the redundant system to the EtherNet/IP network that the FactoryTalk Batch server is running on.

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Notes:

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Chapter 8

IMPORTANT

Information Management Recommendations

Information Management application servers (AppServ-Info) are used for data collection (such as a FactoryTalk® Historian server) or decision support (such as a FactoryTalk® VantagePoint® server).

We recommend that you host FactoryTalk Historian and FactoryTalk VantagePoint applications on separate information management servers.

The following table lists where to find specific information.

Top ic Pag e

FactoryTalk Historian Overview 93

Tips and Best Practices 94

Architectural Best Practices 94

FactoryTalk VantagePoint Overview 94

Tips and Best Practices 94

FactoryTalk Historian Overview

This section provides fundamental best-practice guidelines for implementing FactoryTalk Historian Site Edition (SE) software on PlantPAx® systems.

The FactoryTalk Historian SE product is co-developed with OSIsoft. While the SE software shares many of the same features and functionality available in their Plant Information (‘PI’) product, Rockwell Automation owns the development, documentation, and support of the Historian SE software. References to ‘OSIsoft’ and ‘PI’ are included in the product and the documentation.

In a PlantPAx system, the FactoryTalk Historian SE software collects, stores, and manages data from the plant in the PlantPAx system. The software includes these hardware and software components:

• Data Sources - Plant floor devices and instruments that generate data, typically controllers. Other Data Sources can include external databases.

• Historian SE Interfaces - Compresses and stores the collected data and acts as a data server for Microsoft® Windows-based client applications. It’s also possible to use the Historian SE server to interact with data that is stored in external systems.

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Chapter 8 Information Management Recommendations

• Historian SE Server - Compresses and stores the collected data and acts as a data server for Microsoft Windows-based clients applications. It is also possible to use the Historian SE Server to interact with data that is stored in external systems.

•Historian SE Clients - Microsoft Windows-based applications that are used by plant personnel to visualize the Historian SE data.

Tips and Best Practices

For access to the collection of tips and best practices, refer to Knowledgebase Answer ID 56070 - FactoryTalk Historian SE Tips and Best Practices TOC at https://www.rockwellautomation.custhelp.com

Architectural Best Practices

The following distributed system is representative of how the components can be configured:

• AppServ-Info Historian: Historian SE Server

• PASS: Historian SE Interface, FTLD

• AppServ-Info Reporting: Historian SE Client

• AppServ-OWS, OWS, EWS: Historian SE Client

FactoryTalk VantagePoint Overview

FactoryTalk VantagePoint provides unified access to virtually all manufacturing and plant data sources. The software produces web-based reports, such as dashboards, trends, X-Y plots, and Microsoft Excel® software reports.

The FactoryTalk VantagePoint Trend tool and add-on alarm reports provide advanced analytics.

Tips and Best Practices

For access to the collection of tips and best practices, refer to Knowledgebase Answer ID 59149 - FactoryTalk VantagePoint EMI Tips and Best Practices TOC at https://www.rockwellautomation.custhelp.com

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Chapter 9

Maintenance Recommendations

Good control system maintenance keeps your PlantPAx® system operating efficiently and helps protect the operation of your plant. This chapter provides recommendations for monitoring, backing up data (application and process data), and maintaining your PlantPAx system.

We suggest that you develop a plan to back up your control system configuration and process data on a regular schedule. Consider involving your IT department to develop this plan. An effective backup plan can help protect you from loss of resources and revenue.

Ta b l e 4 0

summaries the types of backups and updates for routine and

annual maintenance. Click the link or see the page for a description of each type.

The time frames are examples, and can be modified based on the attributes and risk factors in your plant.

Table 40 - Maintenance Type Recommendations

Backups Why? When? What?

System - See page 96 Virtual infrastructure disaster recovery Periodic • Host machine

Application configuration - See page 97 Roll back or file protection Periodic • Cont rollers

Data - See page 100

Updates Why? When? What?

Microsoft® operating system - See

page 105

Antivirus - See page 106

Software -See page 106 Periodic and on-demand Rockwell Software

Firmware - See page 106 Control lers

Archive or project protection Periodic and on-demand • FactoryTalk Historian

Resolve known issue and system protection

Periodic Servers and workstations

• PlantPAx virtual images

• Hypervisor management

• PASS servers – FactoryTalk® Directory – HMI, FactoryTalk Linx data servers – FactoryTalk Alarm and Event servers

• Network switches

• Fac toryTa lk Bat ch

• FactoryTalk AssetCentre

Backup and update maintenance schedules are routine maintenance activities, but they have different operational impacts. Updates typically affect system operation while backups typically can be done without an impact on system operation.

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The PlantPAx system can be configured to back up control system configuration data automatically. FactoryTalk AssetCentre software stores data in a SQL server. This safeguard provides a roll back, or pulling back, of earlier protected data that can be used to access data that has since been corrupted or lost.

Data backups for FactoryTalk software packages (Historian, VantagePoint®, AssetCentre) can occur any time without impacting system operation. We recommend that process data backups be routinely scheduled so that data loss is minimized if computer issues occur.

We recommend that you verify operating system or software updates on a non-production system or when the affected system components are not-active. These precautions help to prevent unexpected results. For equipment monitoring and safety, we recommend that you follow the procedures of the manufacturer.

PlantPAx System Backup

When using a virtual infrastructure, follow these consideration for disaster recovery:

• We recommend that the configuration of each host machine is backed up.

• Make periodic backups of your server and workstation virtual images. If

using a traditional environment, backup your servers and workstations.

• If using a hypervisor, backup the hypervisor management software.

The following subsections expand on these considerations.

Host Machine

Host administrator credentials are to be stored in a secure location, respective to each host that is backed up. ESXi server configuration can be backed up by using the command-line interface of the ESXi server or by using a hypervisor management application. The protected information includes the host IP address or DHCP server address.

Virtual Image Disaster Recovery

To retain system configuration with patches and other custom operating system (OS) configurations, we recommend that you back up each PlantPAx system server or workstation. Servers and workstations can be backed up individually by exporting and copying virtual machines (VMs). Each VM can be copied and stored off-site for safekeeping. Do VM maintenance on a dedicated network to prevent any input on your system operation.

Snapshots are not backups, they are change logs. Snapshots can be rendered useless if the base is lost due to host or other system failures. To use storage resources more effectively, back up virtual machines at the virtualization layer.

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Safe, IT-Managed Location

AppServ-Info (SQL)

AppServ-Asset

Alarm and Event AssetCentre Data Asset Framework Events Audit Log

Data Backup

Data

Backup

Data Backup

Backup

FTD Backup

Backup

FactoryTalk Historian

Server

Vant ag ePoi nt

Server

PAS S E WS Fa ct o ry Tal k

Batch

Fac tor yTalk

Hypervisor Management Applications

Many virtual environments leverage the use of a server management platform, such as vCenter Server. Whether this server management is an appliance running on a host or a Windows OS with installed management software, it is to be backed up.

Host management appliances or installations store respective configurations on a database server like SQL, which is typically a local instance. To back up your server management platform, back up the SQL database in accordance with your IT department or other published recommendations.

Application Configuration

Figure 8 - Protect Vital Information with Routine Maintenance

Application configurations for PlantPAx system servers and workstations are to be backed up separately and more regularly. The frequent backups mitigate the risk of losing configuration and application information that was generated between PlantPAx system backups. Frequent backups simplify the process of restoring only a portion of your application, if needed.

Figure 8

system SQL server. The SQL server acts as a central repository for application data in a PlantPAx system.

shows PlantPAx system elements with data flow leading to and from the

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Chapter 9 Maintenance Recommendations

AppServ-Asset

Backup

EWS

The long arrows in Figure 8 represent the flow of data from FactoryTalk Historian and FactoryTalk Batch servers directly to a safe, IT-managed location. An IT-managed storage location accommodates continuous backup data. See page 100

for more information.

Ta b l e 4 1

shows examples of project files that are to be backed up regularly. Some

files contain configuration scripts and collected data.

Table 41 - Recommended Configuration Backup

Configuration Host Environment Tool Files Backed Up

Controller project file Studio 5000® application FactoryTalk AssetCentre Disaster Recovery .ACD

FactoryTalk Directory FactoryTalk Administration Console Distributed Application Manager .APB

PASS servers FactoryTalk View Studio software

Network switches System network User choice .TXT (based)

Figure 8

shows how the individual illustrations complement a comprehensive

maintenance schedule.

Controller Project File

Use FactoryTalk AssetCentre software on your AppServ-Asset server to back up Logix5000™ software and Studio 5000 Logix Designer® application project files (.ACD). Logix5000 assets are created in the AssetCentre project tree for each controller and files can be checked into FactoryTalk AssetCentre software.

A schedule can be created to back up the project files on common intervals. Use an EWS to perform check-out and check-in features to make all modifications to the project file. However, the Logix5000 agent can be hosted on any computer with FactoryTalk AssetCentre Agent installed.

FactoryTalk AssetCentre software is integrated with the Logix Designer application to let you move files back-and-forth without leaving the design environment. Use change tracking on project files to capture all modifications.

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TIP

AppServ-Asset

Fac toryTalk Dire ctor y

Backup

PAS S

AppServ-Asset

Backup

AppServ-Asset

Network Switch

Backup

FactoryTalk Directory

Our recommendation is to back up the FactoryTalk Directory regularly. The backup includes any FactoryTalk security, users, and computers, among other configurations.

The backup is contained in the output .APB file of the Distributed Application Manager, which is installed on the PASS with the FactoryTalk View software, version

8.1 and later.

PASS Servers

The core FactoryTalk View SE project servers need to be backed up each time a change is made to the project, and regularly. The PASS server can comprise HMI, FactoryTalk Linx Data, and Alarm an Event servers.

AssetCentre software, version 9, includes an asset for FactoryView SE version 11. This new asset can be created to support disaster recovery for a FactoryTalk View SE application.

If using an older version, a FactoryTalk AssetCentre custom asset can be created by following the procedure in Knowledgebase Answer ID 818741 at https://

www.rockwellautomation.custhelp.com. The project servers store the output

.APB file to the FactoryTalk AssetCentre server. Schedule the custom asset to run regularly.

Network Switches

AssetCentre software, version 9, includes an asset for managed Stratix switches.

If using an older version of AssetCentre software, back up the network switch configuration to retain the network architecture by using a custom asset. An export of the switch configuration can be generated by using various tools, including the following:

• Studio5000 Logix Designer application software

• Third-party applications, for example the Cisco® Network Assistant Tool

• Command-line interface

• Other desired methods of your IT department

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