PlantPAx Distributed Control System Reference Manual
Reference ManualOriginal InstructionsPlantPAx Distributed Control SystemSystem Release 4.6IMPORTANTThis manual applies to PlantPAx System Release 4.5/4.6.For PlantPAx System Release 5.0, see PROCES-UM100.
Important User InformationRead this document and the documents listed in the additional resources section about installation, configuration, andoperation of this equipment before you install, configure, operate, or maintain this product. Users are required tofamiliarize 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 arerequired 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 maybe impaired.In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting fromthe use or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables andrequirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility orliability 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, orsoftware described in this manual.Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,Inc., is prohibitedThroughout this manual, when necessary, we use notes to make you aware of safety considerations.WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardousenvironment, 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, propertydamage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.Labels may also be on or inside the equipment to provide specific precautions.SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerousvoltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces mayreach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people topotential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALLRegulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Table of ContentsPrefacePurpose of the Reference Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Chapter 1System Architecture OverviewArchitecture Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Critical System Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Procurement Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14141516Chapter 2System ElementRecommendationsPlantPAx Software Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Process Automation System Server (PASS) . . . . . . . . . . . . . . . . . . . . . .PASS Server Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configure the FactoryTalk Directory . . . . . . . . . . . . . . . . . . . . . . .Engineering Workstation (EWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engineering Workstation Application Server (AppServ-EWS) . . . .Operator Workstation (OWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator Workstation Application Server (AppServ-OWS) . . . . . .Independent Workstation (IndWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .AppServ-Info (Historian). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AppServ-Info (VantagePoint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AppServ-Info (SQL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asset Management Server (AppServ-Asset). . . . . . . . . . . . . . . . . . . . . .Batch Management Server (AppServ-Batch) . . . . . . . . . . . . . . . . . . . . .Domain Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controller Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Simplex Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Skid-based Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Determining I/O Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sizing Control Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication PROCES-RM001M-EN-P - June 20191718192020212122232424252526272828293031323
Table of ContentsChapter 3System ApplicationRecommendationsController Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Task Configuration and CPU Utilization . . . . . . . . . . . . . . . . . . .Estimate Controller CPU Utilization . . . . . . . . . . . . . . . . . . . . . . .Use of Program Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tag and Memory Allocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controller-to-Controller Communication . . . . . . . . . . . . . . . . . .Controller I/O Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Add-On Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FactoryTalk View Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Library of Process Objects. . . . . . . . . . . . . . . .Additional Application Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3738404344474851525354Chapter 4Alarm SystemRecommendationsFactoryTalk Alarm and Event Software . . . . . . . . . . . . . . . . . . . . .Using the Library of Process Objects for Alarms. . . . . . . . . . . . . .Alarm State Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring Your Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . .55596063Chapter 5InfrastructureRecommendations4Physical Access Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Infrastructure Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Traditional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Virtual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Virtual PlantPAx Configuration Recommendations . . . . . . . . . . . . .Servers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Virtual Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resource Pool Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . .Domains and Workgroups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Domain Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windows Workgroup Recommendations . . . . . . . . . . . . . . . . . . .Server and Workstation Time Synchronization . . . . . . . . . . . . . .Operating System Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . .Network Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ethernet Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication PROCES-RM001M-EN-P - June 20196566666667676868697272727373747576
Table of ContentsChapter 6Field Device IntegrationRecommendationsDevice Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FactoryTalk AssetCentre for Enterprise Solution . . . . . . . . . . . .EtherNet/IP Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EtherNet/IP I/O Communication Options . . . . . . . . . . . . . . . . .ControlNet Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ControlNet I/O Communication Options . . . . . . . . . . . . . . . . . .DeviceNet Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DeviceNet Communication Options. . . . . . . . . . . . . . . . . . . . . . . .HART Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HART Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . .FOUNDATION Fieldbus Recommendations . . . . . . . . . . . . . . . . . .FOUNDATION Fieldbus Communication Options . . . . . . . .PROFIBUS PA Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PROFIBUS PA Communication Options. . . . . . . . . . . . . . . . . . .Motor Control Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .787878798080818182828383858587Chapter 7Batch Management and Control FactoryTalk Batch Critical System Attributes . . . . . . . . . . . . . . . . . . . 90Batch Guidelines for Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90RecommendationsUsing a Redundant System with a FactoryTalk Batch Server . . . . . . 91Chapter 8Information ManagementRecommendationsFactoryTalk Historian Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tips and Best Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Architectural Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FactoryTalk VantagePoint Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .Tips and Best Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication PROCES-RM001M-EN-P - June 201993949494945
Table of ContentsChapter 9MaintenanceRecommendationsPlantPAx System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Host Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Virtual Image Disaster Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Hypervisor Management Applications . . . . . . . . . . . . . . . . . . . . . . 97Application Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Controller Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98FactoryTalk Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99PASS Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Network Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Data Back up and Restore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Historian Configuration and Data . . . . . . . . . . . . . . . . . . . . . . . . . 100Batch Configuration and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101AssetCentre Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101SQL Server Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Backup Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Retention Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102System Storage Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Security Audit Logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Microsoft Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Use Antivirus Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Software Patches and Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . 106Use Proactive Industrial Security Advisory Index. . . . . . . . . . . . 106Verify Software Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Compare Latest Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . 107Considerations for Software and Firmware Upgrades . . . . . . . . 107Rockwell Automation Services and Support . . . . . . . . . . . . . . . . . . . . 108Appendix AVerify and Monitor Your SystemHealthAdditional Monitoring Resources. . . . . . . . . . . . . . . . . . . . . . . . . . 109Appendix BSystem Software Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1196Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019
PrefaceThe PlantPAx system provides a modern approach to distributed control. Thesystem shares common technology (Integrated Architecture system) with allother automation disciplines in the plant. This approach creates a seamlessinformation flow across the plant for optimization opportunities and enables aConnected Enterprise.Our scalable platform provides you with the flexibility to implement a systemappropriate for your application. Figure 1 shows the documents (this manual inthe highlighted section) that are available to help design and implement yoursystem requirements.Figure 1 - PlantPAx System Implementation and Documentation StrategyDefine andProcureInstall Selection GuidePROCES-SG001 Virtualization User Manual9528-UM001PrepDevelopOperate Infrastructure User ManualPROCES-UM001 Application User ManualPROCES-UM003 Verify and Troubleshoot User ManualPROCES-UM004 Reference ManualPROCES-RM001 Reference ManualPROCES-RM001 Reference ManualPROCES-RM001 Library of Process ObjectsPROCES-RM002PROCES-RM013PROCES-RM014 Define and Procure - Helps you understand the elements of the PlantPAxsystem 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 practicesto follow before you develop your application. Develop - Describes the actions and libraries necessary to construct yourapplication that resides on the PlantPAx system. Operate – Provides guidance on how to verify and maintain your systemsfor efficient operation of your plant.Purpose of the Reference ManualThe PlantPAx Reference Manual builds on the Selection Guide, which specifiessystem sizing guidelines and catalog numbers for procurement. This manualelaborates on the system sizing and application rules that you need to follow toconfigure a PlantPAx system.Rockwell Automation Publication PROCES-RM001M-EN-P - June 20197
PrefaceWe strongly recommend that you use the PlantPAx virtual image templates andRockwell Automation Library of Process Objects for best system performanceand functionality. If you are not able to use the templates or the library, you stillmust follow the guidelines and rules from the Selection Guide and this ReferenceManual. These guide posts make sure that you achieve PlantPAx systemperformance.The PlantPAx system utilizes a set of Critical System Attributes (CSAs) asperformance metrics. Your system performance can meet the CSA metrics if youfollow the sizing guidelines and application rules that are defined in thesedocuments and the PlantPAx System Estimator (PSE).This manual contains new and updated information as indicated in thefollowing table.Summary of ChangesTopicPage120 OWS clients available in distributed architecture14Updates characterized software releases17Adds hard disk size for virtual system elements19, 20, 21, 22,24, 25, 26, 27Updates software components of system elements111These documents contain additional information concerning related productsfrom Rockwell Automation.Additional ResourcesTable 1 - System Core Resources8ResourceDescriptionPlantPAx Distributed Control System Selection Guide,publication PROCES-SG001Provides basic definitions of system elements and sizing guidelines for procuring a PlantPAx system.PlantPAx Distributed Control System InfrastructureConfiguration User Manual, publication PROCES-UM001Provides screen facsimiles and step-by-step procedures to configure infrastructure components for yoursystem requirements.PlantPAx Distributed Control System ApplicationConfiguration User Manual, publication PROCES-UM003Provides the steps necessary to start development of your PlantPAx Distributed Control System.PlantPAx Distributed Control System Verification andTroubleshooting User Manual, publication PROCES-UM004Provides checklist worksheets to verify and document that your system design aligns with PlantPAxsystem recommendations.Rockwell Automation Library of Process Objects,publication PROCES-RM002Provides information on how to use the Rockwell Automation Library of Process Objects.Rockwell Automation Library of Logix Diagnostic Objects,publication PROCES-RM003Provides Add-On Instructions for monitoring and diagnostic information of Logix controllers.Rockwell Automation Library of Steam Table Instructions,publication PROCES-RM004Provides Add-On Instructions for calculating temperature and pressure steam tables.Rockwell Automation Library of Process Objects: LogicInstructions Reference Manual,publication PROCES-RM013Provides controller codes and tags for Rockwell Automation Library objects. The objects are grouped by family andattached as Microsoft Excel files to the manual PDF file.Rockwell Automation Library of Process Objects: DisplayElements Reference Manual,publication PROCES-RM014Provides common display elements for the Rockwell Automation Library. For improved accessibility, the elements arecombined into one manual.Rockwell Automation Publication PROCES-RM001M-EN-P - June 2019
PrefaceTable 1 - System Core ResourcesResourceDescriptionPlantPAx Hardware Specifications and Certifications,publication PROCES-SR027Provides information on PlantPAx system hardware specifications and certifications.PlantPAx Sequencer Object Reference Manual,publication PROCES-RM006Provides a flexible controller-based step sequencing solution that reduces engineering time by automating commonoperator procedures.FactoryTalk View SE Edition User Manual,publication VIEWSE-UM006Provides details on how to use this software package for developing HMI applications that can involve multiple usersand servers, which are distributed over a network.FactoryTalk View SE Instal
This manual elaborates on the system sizing and application rules that you need to follow to configure a PlantPAx system. Define 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 .
Distributed Database Design Distributed Directory/Catalogue Mgmt Distributed Query Processing and Optimization Distributed Transaction Mgmt -Distributed Concurreny Control -Distributed Deadlock Mgmt -Distributed Recovery Mgmt influences query processing directory management distributed DB design reliability (log) concurrency control (lock)
Number Media Cat. Number Physical Media Kit, Software, Virtual Image Template, PlantPAx, Unlicensed – 9528-PASSVTENM Rockwell Automation product activations to be used in conjunction with 9528-PASSVTENM (Microsoft OS licensing not included). PASS Virtual Image Template Activation, Vie
PlantPAx - Virtual Image Templates for Application Server OWS and Application Server EWS, Unlicensed PlantPAx - Virtual Image Template for Asset Management Server, . the eCommerce Manage License Screen. Lock to Email requires the user to activate to an internet computer. The owner or administrator assigns
Distributed Control 20 Distributed control systems (DCSs) - Control units are distributed throughout the system; - Large, complex industrial processes, geographically distributed applications; - Utilize distributed resources for computation with information sharing; - Adapt to contingency scenarios and
The City of Tacoma operates two wastewater treatment plants and the SCADA system for 50 pump stations. The plant control system was recently updated to a Rockwell Automation PlantPAx Distributed Control System. The system communicates with Allen-Bradley PLCs dedicated to specific areas throughout the treatment plants which are
the proposed distributed MPC framework, with distributed estimation, distributed target cal- culation and distributed regulation, achieves offset-free control at steady state are described. Finally, the distributed MPC algorithm is augmented to allow asynchronous optimization and
distributed control approach. The concept of a distributed controller is widely accepted in motion control and factory automation systems [9]. More along the lines of distributed control at the converter level was reported by Malapelle et al. [7] who proposed a distributed &@tal controller for hgh-power drives. They
CCSS Checklist—Grade 2 Writing 1 Teacher Created Resources Writing Text Types and Purposes Standard Date Taught Date Retaught Date Assessed Date Reassessed Notes ELA-Literacy.W.2.1 Write opinion pieces in which they introduce the topic or book they are writing about, state an opinion, supply reasons that support the opinion, use linking words (e.g., because, and, also) to connect opinion and .
