PlantPAx Distributed Control System Reference Manual

PlantPAx Distributed Control System

System Release 4.6

Reference Manual

Original Instructions

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

For PlantPAx System Release 5.0, see PROCES-UM100.

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.

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

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.

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).

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 3

Table of Contents

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

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

Table of Contents

Chapter 3

System Application

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

Alarm System

Recommendations

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

Infrastructure

Recommendations

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

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

Table of Contents

Chapter 6

Field Device Integration

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

Batch Management and Control

Recommendations

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

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

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

Chapter 8

Information Management

Recommendations

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

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

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

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

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

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

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

Health

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

Appendix B

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

Glossary

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

Index

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

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

Preface

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

system shares common technology (Integrated Architecture® system) with all

other automation disciplines in the plant. This approach creates a seamless

information flow across the plant for optimization opportunities and enables a

Connected Enterprise.

Our scalable platform provides you with the flexibility to implement a system

appropriate for your application. Figure 1

shows the documents (this manual in

the highlighted section) that are available to help design and implement your

system requirements.

Figure 1 - PlantPAx System Implementation and Documentation Strategy

• 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.

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

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

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.

Additional Resources

These documents contain additional information concerning related products

from Rockwell Automation.

Topic Page

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,

24, 25, 26, 27

Updates software components of system elements 111

Table 1 - System Core Resources

Resource Description

PlantPAx Distributed Control System Selection Guide,

publication PROCES-SG001

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

PlantPAx Distributed Control System Infrastructure

Configuration User Manual, publication PROCES-UM001

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

system requirements.

PlantPAx Distributed Control System Application

Configuration User Manual, publication PROCES-UM003

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

PlantPAx Distributed Control System Verification and

Troubleshooting User Manual, publication PROCES-UM004

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

system recommendations.

Rockwell Automation Library of Process Objects,

publication PROCES-RM002

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

Rockwell Automation Library of Logix Diagnostic Objects,

publication PROCES-RM003

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

Rockwell Automation Library of Steam Table Instructions,

publication PROCES-RM004

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

Rockwell Automation Library of Process Objects: Logic

Instructions Reference Manual,

publication PROCES-RM013

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.

Rockwell Automation Library of Process Objects: Display

Elements Reference Manual,

publication PROCES-RM014

Provides common display elements for the Rockwell Automation Library. For improved accessibility, the elements are

combined into one manual.

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

Preface

PlantPAx Hardware Specifications and Certifications,

publication PROCES-SR027

Provides information on PlantPAx system hardware specifications and certifications.

PlantPAx Sequencer Object Reference Manual,

publication PROCES-RM006

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

operator procedures.

FactoryTalk® View SE Edition User Manual,

publication VIEWSE-UM006

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.

FactoryTalk View SE Installation Guide,

publication VIEWSE-IN003

Contains procedures for installing FactoryTalk View SE software.

FactoryTalk Alarms and Events System Configuration Guide,

publication FTAE-RM001

Provides details on how to install, configure, and use FactoryTalk Alarms and Events services as part of a

FactoryTalk-enabled automation system.

ControlLogix® System User Manual,

publication 1756-UM001

Explains how to use traditional and extreme environment ControlLogix controllers.

ControlLogix Enhanced Redundancy System User Manual,

publication 1756-UM535

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

greater availability.

Logix5000™ Controllers Design Considerations Reference

Manual, publication 1756-RM094

Details how to design and optimize Logix5000 controller applications.

Logix5000 Controllers Common Procedures Programming

Manual, Publication 1756-PM001

Provides links to a collection of programming manuals that describe how you can use procedures that are common to all

Logix5000 controller projects.

Logix5000 Controllers General Instructions Reference

Manual, publication 1756-RM003

Provides programming controller applications by using relay ladder instructions.

Logix5000 Controllers Advanced Process Control and Drives

Instructions Reference Manual, publication 1756-RM006

Provides details on process control and drives instructions.

Logix 5000 Controllers Execution Time and Memory Use

Reference Manual, publication 1756-RM087

Provides a complete list of instruction execution time and memory usage information for Logix5000 controllers in your

Studio 5000 Logix Designer® programming software.

PlantPAx Logix Batch and Sequence Manager Reference

Manual, publication PROCES-RM007

Explains a controller-based batch and sequencing solution that leverages the Logix Control Platform and

FactoryTalk View software for integrated control and visualization.

Table 2 - Infrastructure Resources

Resource Description

PlantPAx Virtualization User Manual,

publication 9528-UM001

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

EtherNet/IP Network Configuration,

publication ENET-UM001

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

Ethernet Design Considerations Reference Manual,

publication ENET-RM002

Explains the infrastructure components that allow this open network to communicate seamlessly throughout a plant,

from shop floor to top floor.

Converged Plantwide Ethernet (CPwE) Design and

Implementation Guide, publication ENET-TD001

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

Automation Integration Architecture solution.

Troubleshoot EtherNet/IP Networks,

publication ENET-AT003

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

1756 ControlLogix Communication Modules Specifications

Technical Data, publication 1756-TD003

Contains specifications for the ControlLogix network communication modules.

Application Note: Segmentation Methods within the

Cell/Area Zone, publication ENET-AT004

Provides design considerations of network segmentation methodologies for the ControlLogix and

CompactLogix™ 5370 controllers.

Stratix® Managed Switches User Manual,

publication 1783-UM007

Describes the embedded software features and tools for configuring and managing the Stratix 5410, Stratix 5400, and

the Stratix 5700 Ethernet managed switches.

Stratix Ethernet Device Specifications Technical Data,

publication 1783-TD001

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

Stratix/Infrastructure Product Family Quick Reference

Drawing, publication IASIMP-QR029

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

Table 1 - System Core Resources

Resource Description

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

Preface

ControlNet Coax Media Planning and Installation Guide,

publication CNET-IN002

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

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

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

and utilities.

Table 3 - Field Device Integration Resources

Resource Description

FactoryTalk AssetCentre Installation Guide,

publication FTAC-IN005

Provides installation instructions for monitoring your factory automation system.

FactoryTalk AssetCentre Product Profile,

publication FTALK-PP001

Explains this tool for securing, managing, versioning, tracking, and reporting automation-related asset information

across your entire enterprise.

EtherNet/IP and ControlNet to FOUNDATION Fieldbus

Linking Device, publication 1788-UM057

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

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

Contains information on how to install, configure, and troubleshoot ControlLogix HART

analog I/O modules.

Promass 83 Flowmeter via PROFIBUS PA to the PlantPAx

Process Automation System, publication PROCES-AP022

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

DeviceNet System Quick Reference,

publication DNET-QR001

Provides procedures for configuring applications on the DeviceNet® network.

CENTERLINE® Motor Control Centers with EtherNet/IP,

publication 2100-TD031

Describes cable system construction and components that are associated with an EtherNet/IP network that is factory-

installed in CENTERLINE 2100 and CENTERLINE 2500 and IntelliCENTER® motor control centers (MCCs).

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 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

procedures.

FactoryTalk Batch Installation Guide,

publication BATCH-IN002

Provides information and procedures for installing FactoryTalk Batch software.

PlantPAx Batch Design Considerations Reference Manual,

publication PROCES-RM008

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

Batch Application Toolkit Quick Start,

publication IASIMP-QS042

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

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

Table 2 - Infrastructure Resources

Resource Description

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

Preface

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.

Table 5 - Process Safety Resources

Resource Description

Using ControlLogix in SIL 2 Applications Safety Reference

Manual, publication 1756-RM001

ControlLogix components that are supported in SIL 2 configurations.

Redundant I/O System User Manual

publication 1715-UM001

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

Redundancy System.

AADvance Solutions Handbook, publication ICSTT-RM447

Explains the features, performance, and functionality of the AADvance controller and systems. It sets out some

guidelines on how to specify a system to meet your application requirements.

AADvance System Build Manual, publication ICSTT-RM448

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

operation of a controller.

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

Function (SIF) application requirements.

AADvance Safety Manual, publication ICSTT-RM446

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.

AADvance Troubleshooting and Repair Manual, publication

ICSTT-RM406

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

perform routine maintenance tasks.

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

Preface

Notes:

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 13

Chapter 1

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.

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.

Topic Page

Architecture Classes 14

System Elements 14

Critical System Attributes 15

System Procurement Tools 16

EWS PASS

Domain

Controller

Application Servers Multiple OWS

Device Level Ring Topology

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

Chapter 1 System Architecture Overview

Architecture Classes

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

required system.

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.

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

Engineering Workstation (EWS).

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

segregate servers by operating areas.

Station Architecture

Distributed Architecture- Multiple PASS Servers

Distributed Architecture- Single PASS Server

Skid Controller

Table 6 - Architectures and System Elements

System

Element

Skid Architecture Station Architecture Distributed Architecture

(single PASS (consolidated))

Distributed Architecture

(single to multiple PASS servers)

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

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

workstation:

• PASS

• FactoryTalk Historian

• AppServ-Asset Management

• AppServ-VantagePoint

• AppServ-Info (SQL)

IMPORTANT: An additional PASS-C is

required for redundancy.

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).

(1)

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

Can have as many as 5 EWSs.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 15

System Architecture Overview Chapter 1

Critical System Attributes

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

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.

OWS Not applicable. Operator

interface typically

accomplished with PanelView

Plus operator terminal or thin

client connected to 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.

Can have as many as 120 OWS clients.

(1)

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

IMPORTANT: PASS-C supports up to five

redundant controllers.

Use the PlantPAx System Estimator to

verify your design. See page 16

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.

Application

servers

Not applicable. In chassis

historian and in controller

batch capabilities are available.

Can also be integrated with a

distributed architecture.

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 redundancy.

AppServ-Asset Management as needed.

AppServ-Batch as needed.

AppServ-Information Management (SQL,

Historian, or VantagePoint) as needed

AppServ-OWS as needed.

(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

Table 6 - Architectures and System Elements

System

Element

Skid Architecture Station Architecture Distributed Architecture

(single PASS (consolidated))

Distributed Architecture

(single to multiple PASS servers)

Table 7 - CSA Performance Indicators

Critical System Attribute

(1)

Performance

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 performance number. The actual system performance can intermittently deviate from the documented CSA due to system disturbances that can introduce

variability in the network or operating system performance.

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

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

, for more information.

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.

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

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.

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.

Topic Page

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

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

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

FactoryTalk

Network Directory (FTD) server

(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.

FactoryTalk Activation server

(1)

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.

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

HMI server stores HMI project components, such as graphic displays, and serves these components to OWSs upon

request. The HMI server also can manage tag databases and log historical data. Multiple HMI servers can exist on the

PlantPAx system. Each HMI server must be on a separate PASS.

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

the PlantPAx system. FactoryTalk

View software supports two types of data servers: Rockwell Automation Device

servers (FactoryTalk Linx software) and OPC Data servers. The Data server that is mentioned in PlantPAx documentation

generally refers to the Rockwell Automation Device servers. Data servers are configured within your FactoryTalk View

SE application. Multiple data servers can exist on the PlantPAx system.

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

and Event servers are configured within your FactoryTalk View SE application. There are two types of Alarm and Event

servers: device-based and server-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.

Optional

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

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 19

System Element Recommendations Chapter 2

PASS Server Redundancy

PASS servers can be configured as redundant for the following software

components:

• HMI server

• Data server

• Alarm server

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.

IMPORTANT

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.

Table 8.1 - PASS Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 4 vCPU

• 8 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69.

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,

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)

Operating system Windows Server 2016 operating system, 64 bit

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

Chapter 2 System Element Recommendations

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.

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.

IMPORTANT

To configure the FTD, see the PlantPAx Distributed Control System

Infrastructure Configuration User Manual, publication PROCES-UM001

Table 9.1 - EWS Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 100 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows 10 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69

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

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)

Operating system Windows 10 operating system, 64 bit

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 21

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.

Operator Workstation (OWS)

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

the process. The OWS supports operator interaction and is not meant to support

development or maintenance activities, although these activities are possible if

desired.

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 10 - AppServ-EWS Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 4 vCPU

• 8 GB vRAM min

• 100 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

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 sizing only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

Table 11.1 - OWS Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 40 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

(2)

Operating system Windows 10 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69

Table 11.2 - OWS Traditional Requirements

Category Requirement

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

system characterization:

• 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)

Operating system Windows 10 operating system, 64 bit

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

Chapter 2 System Element Recommendations

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.

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

Table 12 - AppServ-OWS Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 8 vCPU

• 16 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• High priority Resource pool

(2)

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 sizing only. The values can be adjusted for system performance if needed.

(2) See Resource Pool Allocation

on page 69

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 23

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)

The independent workstation (IndWS) combines the roles of the PASS, EWS,

and OWS in one computer. This workstation can be used as a ‘shadow system’ for

emergency purposes

Table 13 - IndWS Traditional Requirements

Category Requirement

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

PlantPAx system characterization:

• 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)

Operating system Windows 10 operating system, 64 bit

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

Chapter 2 System Element Recommendations

AppServ-Info (Historian)

The Information Management server can include a historian application to

collect, manage, and analyze data.

AppServ-Info (VantagePoint)

The Information Management server can be used as a decision support tool by

installing VantagePoint software.

Table 14.1 - AppServ-Info (Historian) Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 120 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

(3)

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

(2) See Resource Pool Allocation

on page 69

(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

Table 14.2 - AppServ-Info (Historian) Traditional Requirements

Category Requirement

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

• Intel Xeon Multicore processor (4 cores or greater)

• 2.40 GHz CPU min

• 4 GB RAM min

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

sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit

Table 15.1 - AppServ-Info (VantagePoint) Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69.

Table 15.2 - AppServ-Info (VantagePoint) Traditional Requirements

Category Requirement

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

• Intel Xeon Multicore processor (4 cores or greater)

• 2.40 GHz CPU min

• 4 GB RAM min

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

sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 25

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

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 16.1 - AppServ-Info (SQL) Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 120 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69.

Table 16.2 - AppServ-Info (SQL) Traditional Requirements

Category Requirement

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

• Intel Xeon Multicore processor (4 cores or greater)

• 2.40 GHz CPU min

• 4 GB RAM min

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

sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit

Table 17.1 - AppServ-Asset Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69

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

Chapter 2 System Element Recommendations

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 17.2 - AppServ-Asset Traditional Requirements

Category Requirement

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

• Intel Xeon Multicore processor (4 cores or greater)

• 2.40 GHz CPU min

• 4 GB RAM min

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

sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit

Table 18.1 - AppServ-Batch Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 2 vCPU

• 4 GB vRAM min

• 60 GB vHardDisk

Recommended CPU and memory allocation:

• Normal priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

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

(2) See Resource Pool Allocation

on page 69

Table 18.2 - AppServ-Batch Traditional Requirements

Category Requirement

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

• Intel Xeon Multicore processor (4 cores or greater)

• 2.40 GHz CPU min

• 4 GB RAM min

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

sure that it supports redundant media)

Operating system Windows Server 2016 operating system, 64 bit

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 27

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.

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.

Table 19.1 - Domain Virtual Requirements

Category Requirement

(1)

Virtual infrastructure Required:

• 1 vCPU

• 4 GB vRAM min

• 40 GB vHardDisk

Recommended CPU and memory allocation:

• Low priority Resource pool

(2)

Operating system Windows Server 2016 operating system, 64 bit

(1) All numbers and figures are referenced for initial sizing 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

(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)

Operating system Windows Server 2016 operating system, 64 bit

(1) A Microsoft Excel software license is required.

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

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

(1)

Category Cat. No.

Process controller

(2)

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

EtherNet/IP 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) 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 controllers.

Table 22 - Simplex ControlLogix Controller Sizing

Category

(1)

CompactLogix

1769 -L24ER-QBFC1B

CompactLogix

1769-L19ER-BB1

CompactLogix

1769-L33ER

CompactLogix

1769-L36ERM

User memory 0.75 MB 1.0 MB 2.0 MB 3.0 MB

Total I/O recommended, max 80 125 250 350

Recommended control strategies, max

(2)

10 15 30 45

Total control strategies @ 250 ms, max 10 15 30 45

Total control strategies @ 500 ms, max 10 3000 30 45

Tags/sec delivered to data server, max 3000 3000 3000 3000

(1) These values are recommended maximum limits. To achieve all of these values in a single controller is likely not feasible. For more detailed sizing, you can use the PSE (see page 16).

(2) Maximum controller strategy is based on all controller strategies being simple regulatory control. See Controller I/O Considerations

on page 48.

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

System Element Recommendations Chapter 2

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

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.

One I/O channel per

each device in a

networked, motor

control center.

One I/O channel per each I/O point on an I/O module.

One I/O channel per each device.

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

Chapter 2 System Element Recommendations

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

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

Figure 2 - Control Strategy Example

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

system performance.

POWER

ETHERNET

OKTXDRXD

DIAGNOSTIC

01 234 567

891011121314 15

AC OUTPUT

DIAGNOSTIC

01 234 567

891011121314 15

AC INTPUT ANALOG INPUT

CAL

FLT

01 2345 67

01 234567

891011121314 15

89101112131415

DIAGNOSTIC

ANALOG INPUT

FLT

01 2345 67

01 234567

891011121314 15

89101112131415

DIAGNOSTIC

ANALOG INPUT

RUN

OKFORCE

Logix5573

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 33

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

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.

Complex Regulatory — Primary (outer loop)

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

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 35

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.

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

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 37

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.

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

Topic Page

Controller Recommendations 38

FactoryTalk View Recommendations 52

Rockwell Automation Library of Process Objects 53

Additional Application Resources 54

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

Chapter 3 System Application Recommendations

Table 26 shows memory and CPU recommendations for simplex and

redundant controllers.

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 27

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

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 26 - Simplex and Redundant Controller Memory Recommendations

Environment Simplex Controllers Redundant Controllers

Outside of production environment (before connecting

FactoryTalk® View and Historian clients)

50% free memory to support communication and

handling of abnormal conditions

>50% free memory at all times

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

In the production environment (while FactoryTalk View

and Historian are connected)

25% free memory to support handling of abnormal

conditions

>50% free memory at all times

25% free CPU time 50% free CPU time

Table 27 - Recommended Task Configurations

Name Type Period (ms) Priority (lower number

yields higher priority)

Watchdog (ms) Disable Automatic

Output Processing

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

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

System Application Recommendations Chapter 3

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.

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.

Figure 3 - Task Execution Example

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,

and alarm instruction processing.

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

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

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 41

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).

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

Chapter 3 System Application Recommendations

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

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.

IMPORTANT

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 43

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

Figure 4 - CPU Utilization

For more information, see the Rockwell Automation Library of Logix Diagnostic

Objects Reference Manual, publication PROCES-RM003

Use of Program Parameters

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.

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

Task Time

Comms IO Monitor

18.42%

Comms

IMPORTANT

The number of program parameters—Input, Output, InOut, Public —are

limited to 512 parameters per program.

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

Chapter 3 System Application Recommendations

Tag and Memory Allocation

Table 28 shows the memory of a controller is divided into several areas depending

on the type of controller.

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.

Table 28 - Controller Memory Allocation

Controller Type Storage Memory

1756 ControlLogix

1768 CompactLogix

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

(1)

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

(1)

UDT and Add-On Instruction definition

1769-L2x CompactLogix

1769-L3x CompactLogix

1769-L19x CompactLogix

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

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 45

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.

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

Chapter 3 System Application Recommendations

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

• Used 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.

Controller Properties icon

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 47

System Application Recommendations Chapter 3

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

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

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

• 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

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 reserved up front

• Does not impact the scan of the controller

• 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 backplane 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.

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

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.

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 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

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 actual 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.

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

• Cache messages when the message needs only to be maintained all 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).

Table 31 - I/O Considerations

Category Consideration

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

– 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.

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

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

Considerations.) 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

EtherNet/IP network See Chapter 5 for infrastructure recommendations.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 49

System Application Recommendations Chapter 3

I/O Module Runtime/Online Considerations

Table 32 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

Module Type and

Connection Method

In Local Chassis Remote Via a ControlNet Network Remote Via an

EtherNet/IP Network

Configure Hold Last

Output State

Offline Runtime Offline Runtime Offline Runtime

Scheduled Unscheduled Scheduled Unscheduled

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

output modules

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

output modules

Analog - direct Yes Yes Yes Yes No Yes Yes Yes Yes

Generic third-party - direct Yes Yes Yes Yes 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-party

- direct

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

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

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

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

modules only

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

(1)

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

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

Chapter 3 System Application Recommendations

When you design your network, review these considerations if you are going to

add I/O modules at runtime.

See the Logix5000 Controllers Design Considerations Reference Manual,

publication 1756-RM094

, for more information.

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.

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, reserve some connection points on the switch so that you can connect additional nodes or switches in

the future.

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

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.

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

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 51

System Application Recommendations Chapter 3

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

and page 59.

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

Chapter 3 System Application Recommendations

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 53

System Application Recommendations Chapter 3

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.

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.

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

Chapter 3 System Application Recommendations

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

The following resources are available for use to assist with developing

your application.

Topics and Tools Description Where To Find Information

System deployment guide Provides procedures that are necessary to start

development of your PlantPAx system.

See the PlantPAx Distributed Control System Application

Configuration User Manual, publication PROCES-UM003

FactoryTalk Diagnostic sample displays Sample graphics to display FactoryTalk Linx

sample counters.

See the Knowledgebase Answer ID 30148 at

http://rockwellautomation.custhelp.com

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

and state by using VBA and displaying the status on the

HMI display.

See the Knowledgebase Answer ID 44624 at

http://rockwellautomation.custhelp.com

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

configuring an Integrated Architecture System.

http://www.rockwellautomation.com/solutions/

integratedarchitecture/resources.html

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

Rockwell Automation products, including Rockwell

specific faceplates.

http://samplecode.rockwellautomation.com/idc/groups/

public/documents/webassets/sc_home_page.hcst

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

guide you to the best design decisions for batch

system implementation.

See the Batch Application Toolkit Quick Start,

publication IASIMP-QS042

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 55

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.

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.

Topic Page

FactoryTalk Alarm and Event Software 55

Using the Library of Process Objects for Alarms 59

Alarm State Model 60

Monitoring Your Alarm System 63

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

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

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

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.

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.

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

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.

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

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.

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:

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

alarm information.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 57

Alarm System Recommendations Chapter 4

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

, for more

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.

See the FactoryTalk View Site Edition User's Guide,

publication VIEWSE-UM006,

for more information on

alarm expressions.

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

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 identify 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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 59

Alarm System Recommendations Chapter 4

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

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

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

Chapter 4 Alarm System Recommendations

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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Alarm System Recommendations Chapter 4

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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Chapter 4 Alarm System Recommendations

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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Chapter 4 Alarm System Recommendations

Notes:

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 65

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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Chapter 5 Infrastructure Recommendations

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.

Topic Page

Virtual PlantPAx Configuration Recommendations 67

Operating System Recommendations 72

Network Recommendations 75

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Infrastructure Recommendations Chapter 5

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.

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.

IMPORTANT

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.

IMPORTANT

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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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/full-

duplex’ or ‘100MB/full-duplex’ if required by the network hardware.

IMPORTANT

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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Infrastructure Recommendations Chapter 5

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.

IMPORTANT

In a PlantPAx system, make sure that the PASS servers and workstations have

higher priority for consistent performance.

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Chapter 5 Infrastructure Recommendations

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 Table 3 4

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.

Table 34 - Server Resource Pool Allocation

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

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

virtual template

PAS S

OWS

AppServ-OWS

Normal Normal Zero Normal Zero EWS

AppServ-EWS

AppServ-Asset

AppServ-Batch

AppServ-Info

Low Low Zero Low Zero FactoryTalk® Directory

Domain Controller

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Infrastructure Recommendations Chapter 5

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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Chapter 5 Infrastructure Recommendations

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.

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.

• 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.

Configuration Details

Workgroup - decentralized administration

(allowed if 10 or fewer computers)

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

Workgroup rules:

• 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 - centralized administration

(recommended)

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.

TIP

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.

IMPORTANT

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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Infrastructure Recommendations Chapter 5

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]

The w32tm/resync

command manually forces a computer to resynchronize its

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

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.

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Chapter 5 Infrastructure Recommendations

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

for more information on how to

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.

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Infrastructure Recommendations Chapter 5

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.

• 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.

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,

or the PlantPAx Selection

Guide, publication PROCES-SG001

IMPORTANT

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.

Type Details

Fiber-optic • Long distances

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

• For extreme high-noise environments

• For poorly grounded systems

• For outdoor applications

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

• Use termination sequence 568A for industrial applications

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Chapter 5 Infrastructure Recommendations

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.

Select the switch depending on the network functionality.

Additional Switch Information

See the Stratix Ethernet Device Specifications Technical Data,

publication 1783-TD001

, for information on these switch components:

• 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)

IMPORTANT

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.

If Then

• Supervisory

• Routing information to other networks

Layer 3 switches

(1)

• Stratix 5410

• Stratix 5400

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

• Connecting control hardware, sensors, and workstations

• Isolated networks

Layer 2 switches

(1)

• Stratix 5410

• Stratix 5400

• Stratix 5700

High availability at switch level Layer 3 switch

(1)

• Stratix 5410

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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.

Topic Page

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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Chapter 6 Field Device Integration Recommendations

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

ControlLogix EtherNet/IP bridge.

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.

1788-EN2PAR EtherNet/IP to PROFIBUS PA linking device. Supports PA media. Compatible with

ControlLogix redundancy. Built-in functionality for the Ethernet DLR.

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Field Device Integration Recommendations Chapter 6

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

on page 8 for

more information.

IMPORTANT

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.

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

Chapter 6 Field Device Integration Recommendations

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.

Follow these guidelines for ControlNet networks:

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

on page 8 for

more information.

Table 35 - ControlNet Interface

Category Product Description

ControlLogix controller interface 1756-CN2, 1756-CN2R

1756-CNB, 1756-CNBR

ControlLogix ControlNet scanner.

1788-CN2FFR ControlNet to FOUNDATION Fieldbus linking device. Supports H1 FOUNDATION

Fieldbus networks. Compatible with ControlLogix redundancy and redundant

ControlNet media.

1788-CN2PAR ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media

and redundant ControlNet media. Compatible with ControlLogix redundancy.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 81

Field Device Integration Recommendations Chapter 6

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.

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

on page 8 for

more information.

Table 36 - DeviceNet Interface

Category Product Description

ControlLogix controller interface 1756-DNB ControlLogix DeviceNet scanner.

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

Chapter 6 Field Device Integration Recommendations

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.

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

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

through the I/O tree, provide status and diagnostics information, and provide remote

configuration and troubleshooting.

Distributed I/O, high-channel density 1794-IE8H, 1794-OE8H,

1794-IF8IH, 1794-OF8IH,

1794-IF8IHNFXT

FLEX analog I/O modules with the following:

• Standard profiles in Studio 5000 Logix Designer

• DTMs

Distributed I/O, low-channel density 1734-sc-OE2CIH, 1734-sc-IF4H Spectrum Controls, analog input module with HART for the POINT I/O™ system.

1769-sc-IF4IH, 1769-sc-OF4IH Spectrum Controls, analog, isolated input and output modules with HART

for Compact I/O™ modules.

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

(1)

product offerings.

Network configuration Handheld device Endress+Hauser

(1)

, handheld configuration and diagnostic device.

See the Encompass website for Endress+Hauser product offerings.

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 83

Field Device Integration Recommendations Chapter 6

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.

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.

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

(1)

, FOUNDATION Fieldbus components, such

as valve couplers, surge protectors, and distributors.

See the Encompass website for Pepperl+Fuchs product

offerings.

Segment protection Helps protect against device or line faults with short- and open-

circuit protection.

Pepperl+Fuchs

(1)

, intrinsic safety components, such as isolated

barrier systems, hazardous area enclosures, and equipment.

See the Encompass website for Pepperl+Fuchs product

offerings.

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

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

Chapter 6 Field Device Integration Recommendations

• Use only two terminators per bus segment to help prevent distortion and

signal loss. Terminators are placed at the ends of the trunk.

IMPORTANT

Each linking device, whether configured with a simplex or redundant

controller, can support one H1 segment.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 85

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

on page 8 for

more information.

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

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.

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.

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

and redundant ControlNet media. Compatible with ControlLogix redundancy.

Built-in functionality for the Ethernet DLR.

1788-CN2PAR ControlNet to PROFIBUS PA linking device. Supports redundant PROFIBUS PA media

and redundant ControlNet media. Compatible with ControlLogix redundancy.

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

(1)

, FOUNDATION Fieldbus components, such as valve couplers, surge

protectors, and distributors.

See the Encompass website for Pepperl+Fuchs product offerings.

Segment protection Helps protect against device or line faults with short- and open-circuit protection.

Pepperl+Fuchs

(1)

, intrinsic safety components, such as isolated barrier systems,

hazardous area enclosures, and equipment.

See the Encompass website for Pepperl+Fuchs product offerings.

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 87

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

on page 8 for

more information.

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

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 89

Field Device Integration Recommendations Chapter 6

Notes:

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 89

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

and Knowledgebase Answer ID 62366 at

http://www.rockwellautomation.custhelp.com

for more information on LBSM.

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.

Topic Page

FactoryTalk Batch Critical System Attributes 90

Batch Guidelines for Logix 90

Using a Redundant System with a FactoryTalk Batch Server 91

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

Chapter 7 Batch Management and Control Recommendations

FactoryTalk Batch Critical

System Attributes

The following critical system attributes (CSA) were used to verify performance

for FactoryTalk Batch during process system characterization.

Batch Guidelines for Logix

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.

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 91

Batch Management and Control Recommendations Chapter 7

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.

Logix 556x

Logix 556x Logix 556x





















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

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

Chapter 7 Batch Management and Control Recommendations

Notes:

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 93

Chapter 8

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).

The following table lists where to find specific information.

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.

IMPORTANT

We recommend that you host FactoryTalk Historian and FactoryTalk

VantagePoint applications on separate information management servers.

Topic Page

FactoryTalk Historian Overview 93

Tips and Best Practices 94

Architectural Best Practices 94

FactoryTalk VantagePoint Overview 94

Tips and Best Practices 94

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

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

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 95

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.

Table 40

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.

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.

Table 40 - Maintenance Type Recommendations

Backups Why? When? What?

System - See page 96 Virtual infrastructure disaster recovery Periodic • Host machine

• PlantPAx virtual images

• Hypervisor management

Application configuration - See page 97 Roll back or file protection Periodic • Controllers

• PASS servers

– FactoryTalk® Directory

– HMI, FactoryTalk Linx data servers

– FactoryTalk Alarm and Event servers

• Network switches

Data - See page 100

Archive or project protection Periodic and on-demand • FactoryTalk Historian

• FactoryTalk Batch

• FactoryTalk AssetCentre

Updates Why? When? What?

Microsoft® operating system - See

page 105

Resolve known issue and system

protection

Periodic Servers and workstations

Antivirus - See page 106

Software -See page 106 Periodic and on-demand Rockwell Software

Firmware - See page 106 Controllers

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

Chapter 9 Maintenance Recommendations

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.

Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019 97

Maintenance Recommendations Chapter 9

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

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

shows PlantPAx system elements with data flow leading to and from the

system SQL server. The SQL server acts as a central repository for application

data in a PlantPAx system.

Figure 8 - Protect Vital Information with Routine Maintenance

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

VantagePoint

Server

PAS S EWS Fac tor yTalk

Batch

FactoryTalk