Home

- Rockwell Automation

Contents

1. Valves and Instrumentation Rockwell Automation Publication PROCES RM001F EN P October 2011 17 Chapter2 System Element Recommendations PlantPAx Software Components Process Automation System Server PASS Software Components FactoryTalk Network Directory server Integrated Architecture software components and versions that comprise the PlantPAx system release 2 0 include the following e RSLogix 5000 software version 19 x e FactoryTalk View software version 6 00 00 e FactoryTalk Batch software version 11 00 00 e FactoryTalk AssetCentre software version 4 00 00 e FactoryTalk VantagePoint software version 3 00 00 e FactoryTalk Historian software version 2 20 00 Additional tools and libraries are available that when combined with Integrated Architecture software components greatly enhance PlantPAx capabilities For example the PlantPAx Process Library is a predefined library of control code faceplates and display elements designed to allow a process user to quickly assemble large applications with proven strategies and expected results See Chapter 3 for more information The process automation system server PASS is a required system element that contains these Rockwell Automation Integrated Architecture software components Description Secures information from multiple Rockwell Automation software components across multiple computers and allows central a
2. 18 Rockwell Automation Publication PROCES RM001F EN P October 2011 System Element Recommendations Chapter 2 IMPORTANT Ifyou are using FactoryTalk Batch the batch components should be installed before any other FactoryTalk components See page 64 for details If a domain is used add the PASS to the domain before installation See page 45 for details Set Up the FactoryTalk Directory Before starting a project you must install FactoryTalk Directory services on the PASS The FactoryTalk Directory server manages applications that may exist on multiple clients and servers on separate computers on the PlantPAx system IMPORTANT Itis required to have a username and password with Administrator privileges to install FactoryTalk software and to specify a FactoryTalk Directory location Use the same username and password for all FactoryTalk installations on the PlantPAx system After Rockwell Automation software components are installed you need to specify the FactoryTalk Directory location on all servers and workstations Specify the location as follows e Localhost on the PASS server e Name of the PASS server on each APPServ HMI OWS EWS and so forth Do these configuration steps 1 On each server and workstation hosting a PASS Application Server EWS or OWS choose Start Programs Rockwell Software FactoryTalk Tools Specify FactoryTalk Directory Location The FactoryTalk Directory Server Location Utility appears
3. rockwellautomation custhelp com 62367 62372 67642 Rockwell Automation Publication PROCES RM001F EN P October 2011 43 Chapter3 System Application Recommendations Notes 44 Rockwell Automation Publication PROCES RM001F EN P October 2011 Operating System Recommendations Configuration Workgroup decentralized administration 10 or fewer computers Chapter 4 Infrastructure Recommendations The PlantPAx system infrastructure is built on an IT infrastructure based on commercial off the shelf technologies such as Microsoft Windows and open network technologies to allow for seamless integration between system elements and to higher level business systems This chapter outlines recommendations for setting up the infrastructure components to achieve optimal performance of the PlantPAx system Operating System Recommendations Network Recommendations 51 The following recommendations apply regardless of 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 Details Workgroup advantages e No domain controller Windows Server 0S to purchase or maintain Recommended only for small PlantPAx applications where user accounts do not change often Workgroup rules All workstation and server system elements
4. Category Product Description PROFIBUS interface 1788HP EN2PA R EtherNet IP to PROFIBUS PA linking device from HIPROM Technologies a Rockwell Automation company Supports redundant PA media and DLR capable Ethernet Linking device includes power conditioning 1788HP CN2PA R ControlNet to PROFIBUS PA linking device from HIPROM Technologies a Rockwell Automation company Supports redundant PA media and redundant ControlNet media Linking device includes power conditioning PROFIBUS network components Power conditioning Linking devices have built in power conditioning Product is from HIPROM Technologies a Rockwell Automation company Junction boxes Intelligent junction box PAR JB 4 junctions and PAR JB6 6 junctions support redundancy and do not require separate power supplies Product is from HIPROM Technologies a Rockwell Automation company PROFIBUS network components Power conditioning Pepperl Fuchs PROFIBUS components such as valve couplers surge protectors terminators distributors and power products See the Encompass website for Pepperl Fuchs product offerings Terminators Segment protection See the documentation listed in Additional Resources on page 10 for more information 62 Rockwell Automation Publication PROCES RM001F EN P October 2011 FactoryTalk Batch Critical System Attributes Table 24 FactoryTalk Batch CSA Batch Critical System Attribute Idle state start command
5. Chapter 6 Batch Management and Control Recommendations PlantP Ax batch management and control includes two options for a scalable solution e Controller based single unit or multiple independent unit solution LBSM e AppServ Batch for a comprehensive batch solution FactoryTalk Batch Logix Batch and Sequence Manager LBSM is the controller based solution consisting of controller code and visualization elements for use on Logix5000 and FactoryTalk View software Refer to the PlantPAx Selection Guide and Knowledgebase Answer ID 62366 at http www rockwellautomation custhelp com for more information on LBSM AppServ Batch uses Factory Talk Batch software for a comprehensive server based solution that leverages core Logix functionality PhaseManager This chapter provides basic setup information for a comprehensive batch solution by using FactoryTalk Batch software The following table describes what this chapter contains and where to find specific information Topic Page FactoryTalk Batch Critical System Attributes 63 Install FactoryTalk Batch Client Components 64 FactoryTalk Batch Application Guidelines 65 Batch Guidelines for Logix 65 The following critical system attributes CSA were used to verify performance for FactoryTalk Batch during process system characterization Performance The time from the start command to the first scan of the running routine is no more than 1 second Running s
6. Never have anything 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 Auto device replace ADR can take devices installed with the default node address of 63 and place them in the configuration at the missing node address and download configuration parameters to the new device ADR only has 1 MB worth of data Some large drives contain 10 KB so networks may need to be split across multiple scanners When configuring ADR upload all network devices first so that the ADR files contain the correct configuration For ADR key the Vendor Product Type Product Code Major Revisions and Minor Revisions Auto Address Recovery should be disabled Configuration Recovery should be enabled Store EDS files in a common location so they can be installed on engineering workstations Create logic to monitor network health for critical applications 58 Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 20 DeviceNet Interface Field Device Integration Recommendations Chapter 5 e Extended attributes are explicitly messaged back instead of continually polled e Keep the Interscan Delay gt 5 ms e Keep data sizes to 8 bytes or less to prevent fragmentation which reduces bandwidth e Set DeviceNet scanner RPI time to half the scan rate of the fastest task in the controller that uses data on that DeviceNet networ
7. add a Prestate routine to the phase program and put the timer in there Use an enable bit that is set and reset within the phase state routines to control it For SEC any conditional code that is required for transitions such as a transition to the next step on a timer done should be implemented by using separately defined phase tags as opposed to step tag attributes This prevents errors when copying sequencer logic because the SFC editor automatically assigns new step and transition tag names Select an equipment phase action on loss of communication with an external procedure such as a FactoryTalk Batch application For example select Hold Equipment Module Acquire requests phase ownership should be cleared in the phase Resetting state Rockwell Automation Publication PROCES RM001F EN P October 2011 65 Chapter6 Batch Management and Control Recommendations Notes 66 Rockwell Automation Publication PROCES RM001F EN P October 2011 Maintaining Your System Chapter 7 Maintenance Recommendations Good maintenance practice will keep your PlantPAx system running efficiently This chapter provides some recommendations for monitoring and maintaining your PlantPAx system The following table describes what this chapter contains and where to find specific information Topic Page Maintaining Your System 67 Monitoring Your System 69 Services and Support 7 When installing PlantPAx system elements we recommend
8. defined tag UDT workstation Glossary The operator workstation OWS provides the graphical view and interface into the process The workstation is a client of either a PASS or AppServ HMI A defined set of standard Rockwell Automation Integrated Architecture products that are configured in a prescribed way to provide optimal performance as a process automation system The Process Automation System Server PASS is the core PlantPAx system server allowing central administration throughout the PlantPAx system The PASS is a required component RSLinx software is the communication driver data server for computer based programs to access information in Rockwell Automation controllers There is RSLinx Classic software and RSLinx Enterprise software FactoryTalk View SE software uses RSLinx Enterprise software to directly access tags Software component that serves data to an application for example data server Typically server software components are installed on server class computers A system attribute is an operational functionality that can be manipulated or measured and is used to establish the operational boundaries or system capability For example workstation memory number of parameters on a screen and number of control loops A system attribute can be independent or dependent System element is a distinctive system entity made up of a combination of hardware and software products that support an identifiable system
9. xi Use this dialog to change the Network directory that this computer belongs to This setting affects all software that connects to the Network directory from this computer r Use the FactoryT alk Directory installed on o Computer hosting directory server connected Cancel ocalho a 2 In the Computer hosting directory server connected box do the following a Type localhost if you are configuring the PASS server b Click Browse E and select the PASS server name if configuring an Application Server EWS or OWS c Click OK See the FactoryTalk View SE Installation Guide publication VIEWSE IN003 for more information on FactoryTalk View installations Rockwell Automation Publication PROCES RM001F EN P October 2011 19 Chapter2 System Element Recommendations Engineering Workstation EWS Operator Workstation OWS PASS Server Redundancy The following PASS Server software components can be made redundant e FactoryTalk View HMI Server e FactoryTalk View Data Server e FactoryTalk View Alarm and Event Server All of these can be made redundant through the server properties dialog box within the FactoryTalk View application When enabling redundancy in FactoryTalk View Studio select the option to Continue using the secondary server even when the primary server becomes available again to avoid excessive switchovers and to be able to manage replication of application changes made before or
10. 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 listing of all instruction execution time and memory usage information for Logix5000 controllers firmware revision 18 11 except ControlLogix 1756 L7x controllers that use firmware revision 18 12 in your RSLogix 5000 programming software version 18 00 program 1756 ControlLogix Controllers Technical Data publication 1756 TD001 Contains specifications for ControlLogix controllers PlantPAx Server and Workstation User Manual publication 7477 UM001 Explains how to configure prepackaged PlantPAx servers and workstations Infrastructure PlantPAx Process Automation System Selection Guide publi
11. after the switchover occurs The FactoryTalk Directory server does not require redundancy The FactoryTalk Directory information is cached on each computer that is participating in a distributed application If the FactoryTalk Directory server computer is disconnected from the network or fails the OWS EWS and other application servers can continue to access everything within the application as long as the computer had previously accessed the FactoryTalk Directory server The engineering workstation EWS is the central location for monitoring and maintaining the system operation Software components that need to be installed include the following e RSLogix 5000 Professional Edition e RSNetWorx for ControlNet depending on your architecture requirements e FactoryTalk View Site Edition Studio and Client e FactoryIalk Batch Client software If a batch application server is used the FactoryTalk Batch client and editor components are required to configure the FactoryTalk Batch system and setup the FactoryTalk objects on the displays The operator workstation OWS provides a graphical interface for the operator it s not meant to support development or maintenance activities The OWS is a client of either a PASS server or AppServ HMI Software components that need to be installed include the following e FactoryTalk View Site Edition SE client software The OWS also may contain clients for non core application servers suc
12. free memory available at all times for redundant controllers Controller User Tasks last scan max scan overlap L_TaskMon or RSLogix 5000 Task Properties Window Make sure you are not experiencing task overlap by verifying the task overlap count is 0 Task overlap indicates that the controller may be overloaded and may not be executing as expected Controller Minor Faults RSLogix 5000 Controller Properties Window Make sure you are not experiencing any minor faults This may slow your controller execution time or may indicate some other problem with your user logic Packets per second 70 L_CPU or RSLinx Enterprise pre defined tags Make sure the packets per second is less than 300 on the 1756 17x controller and less than 200 on the 1756 L6x controller If you have more than one data server topic pointing to the controller you have to add the packets per second for each topic to get a total Rockwell Automation Publication PROCES RM001F EN P October 2011 Maintenance Recommendations Chapter 7 Check Paging Utilization Virtual memory is the use of hard disk space to supplement the amount of physical memory RAM that is available to the computer Windows cannot process data directly from virtual memory If Windows needs to do something with data that is in virtual memory it must move the page containing the needed data from virtual memory into physical memory This process is called paging Windows mus
13. historical data HMI servers are configured within your FactoryTalk View SE application FactoryTalk View Data server The Data server component provides access to information from the process controllers to the HMI server and OWS station FactoryTalk View supports two types of data servers Rockwell Automation Device servers RSLinx Enterprise and OPC Data servers The Data server 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 Alarms and Events server The Alarms and Events server is an optional component on the PASS that makes alarm information from controllers and servers available to all subscribing OWS stations Alarms and Events servers are configured within your FactoryTalk View SE application There are two types of Alarms and Events servers device based alarm and event servers that is configured as an option to the data server and server based alarm and event servers configured as a separate component The Alarms and Events server mentioned in PlantPAx documentation refers to the Alarms and Events server that is used for server based alarms You can have up to two Alarms and Events servers on the PlantPAx system These may exist on the PASS or an AppServ HMI Optional FactoryTalk Batch client software 30 If a Batch App
14. option For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support 72 Rockwell Automation Publication PROCES RM001F EN P October 2011 Add On Instruction AOI application server architecture characterization client control strategy Glossary The following terms and abbreviations are used throughout this manual For definitions of terms not listed here refer to the Allen Bradley Industrial Automation Glossary publication AG 7 1 An Add On Instruction contains user defined code that has logic encapsulated into pre validated modules and can be reused without modification This lets you create standardized libraries that can both reduce project development time and support costs The application server AppServ is a server in addition to the Process Automation System Server PASS that is typically a FactoryTalk Directory client of the PASS There could be an AppServ HMI for a FactoryTalk View application AppServ Batch for a FactoryTalk Batch application or AppServ History for an Historian application An architecture is a representation ofa control and software system as well as the process and discipline for effectively implementing the designs for such a system An architecture conveys the information content of the related elements comprising a system the relationships among those elements and the rules governing those relationsh
15. remove all protocols other than TCP IP Use static IP addresses Consider cable type for environmental conditions Details 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 e Use termination sequence 568A for industrial applications Refer to these publications for additional information For fiber cable specifications and an example of dB loss see Appendix C in the EtherNet IP Modules Installation Instructions ENET IN002 For selecting architecture see the EtherNet Design Considerations Reference Manual publication ENET RM002 or the PlantPAx Selection Guide publication PROCES SG001 Rockwell Automation Publication PROCES RM001F EN P October 2011 51 Infrastructure Recommendations Chapter 4 Table 16 Ethernet Switches If e Supervisory e Routing information to other networks Ethernet Switches The supervisory network should 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 e The first switch that Rockwell Automation equipment touches should have IGMP snooping enabled IGMP snooping enables switches to forward multicast packets only to ports that are
16. strategies have been established as system footprints e Simple digital e Complex digital e Simple analog non PID e Simple analog PID e Complex analog cascaded PID e Digital indicator e Analog indicator The example diagram shows an example of the application code required for an analog indicator control strategy Each physical device maps to a controller code element and to a display element and faceplate System sizing takes into account other loading concerns related to the control strategy such as data logging and alarming Figure 2 Analog Indicator Example HMI Overview Screen O 2 een Faceplates Sees Data Log me Controller Code Analog Input Analog Input 5 alarm tags 5 ack tags 119 HMI faceplate tags Hist 1 tag Datalog 1 tag Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 10 1 0 Considerations Attribute 1 0 configuration properties System Element Recommendations Chapter 2 The table shows details in Figure 2 for these base control strategies Table 9 Base Control Strategy Estimated Loading Control Strategy Controller Execution Time ms Controller Memory KB Simple regulatory 0 68 8 7 Complex regulatory 1 39 11 9 Simple digital 0 33 5 1 Complex digital 1 08 13 5 Analog indicator 0 28 33 Digital indicator 0 11 2 5 The following occurs when using redundant controllers e Sc
17. that are configured in a prescribed way for optimal performance as a process automation system This section provides a description of the architectures and system elements that you can use to assemble a PlantPAx system and the system performance attributes that you should be able to achieve when following the recommendations of this manual The following table describes what this chapter contains and where to find specific information Topic Page Architecture Classes 14 System Elements 15 Critical System Attributes 15 System Procurement Tools 16 Rockwell Automation characterizes a process automation system based on its size or architecture class A characterized system tested classification yields system performance data and recommended hardware and software configurations The classes of PlantPAx architecture offer system scalability while organizing IA products consistent with process industry expectations The architecture classes shown in the illustration are described as the following e Independent system architecture for single unit control e Centralized system architecture for area control e Distributed system architecture for plant wide operations Distributed Centralized Independent pul Rockwell Automation Publication PROCES RM001F EN P October 2011 13 Chapter1 System Architecture
18. that you use the operating systems and Rockwell Automation software and firmware versions as specified in the PlantPAx Selection Guide publication PROCES SGO001 The selection guide specifies the optimal performance in accordance to sizing criteria The software versions for PlantPAx System Release 2 0 are listed on page 18 Microsoft Updates Microsoft releases a range of security updates operating system and other software updates Rockwell Automation qualifies certain MS updates that potentially impact Rockwell Automation software products The results of these patch qualifications are published on Knowledgebase Answer ID 35530 at http www rockwellautomation custhelp com We recommend that you do not apply or install Microsoft updates until they are qualified by Rockwell Automation Before implementing qualified MS updates you should verify them on a non production system or when the facility is non active to ensure that there are no unexpected results or side effects You can contact Rockwell Automation Technical Support if additional information or details are required Rockwell Automation Publication PROCES RM001F EN P October 2011 67 Chapter 7 68 Maintenance Recommendations Antivirus Software It is best practice to have antivirus software installed on your PlantPAx servers and workstations See Knowledgebase Answer ID 35330 for more information on compatibility and considerations when installing antivi
19. this after changes are made replicate them to the secondary HMI server Monitor the status of the secondary server to make sure it returns to Standby status e The number of HMI classic alarms per application should be limited to 40 000 total of which no more than 10 000 can be analog tags Rockwell Automation Publication PROCES RM001F EN P October 2011 41 Chapter3 System Application Recommendations General FactoryTalk Alarm Recommendations Use an alarm class to group alarms based on their function For example groupings that make it easier for operators to identify alarms related to bad I O controller deviation device failures or valves that fail to open or close Use a tag naming convention that lets you group alarms by location to enable rolled up indicators by using alarm expressions in FactoryTalk View SE to retrieve alarm counts by name The number of FactoryTalk alarms per application should be limited to 20 000 total FactoryTalk Server based Alarm Recommendations The Tag Alarm and Event server and the Data server which collects the information for the Tag Alarm and Event server must both be hosted on the same server An application is limited to two Tag Alarm and Event servers per application For large applications consider separating the data server used for alarms and events from the data server used for display data You can do this by creating a separate AppServ HMI that contains only the alarm and even
20. 1 0 modules on a unscheduled remote 1 0 ControlNet network 80 ControlNet module use For 1756 CN2 1756 CN2R modules this means 2048 1 0 modules Controlnet module For 1756 CNB 1756 CNBR modules this means 1024 1 0 modules per ControlNet module 25 50 ms RPI Unscheduled 20 ControlNet interface modules per controller Use 1756 CN2R module in local chassis If changes are made to the ControlNet configuration upload the configuration to make sure it gets backed up to the RSLogix 5000 project Follow these guidelines for ControlNet networks When configuring the ControlNet network select Optimize and re write schedule for all connections 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 use more than 80 of the ControlNet module Keep SMAX and UMAX values as small as possible to improve performance Do not leave any ControlNet node addressed 99 this is the default address on some new devices If changes are done to the ControlNet configuration make sure it gets backed up to the RSLogix 5000 program by doing an upload Maximum of five controllers with a rack optimized listen only connection to the module Maximum of 64 I O modules on an unscheduled remote I O ControlNet network Rockwell Automation Publication PROCES RM001F EN P October 2011 57 Chapter5 Field Device Integr
21. EN P October 2011 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures Unite
22. Field Device Integration Recommendations Table 21 HART Interface 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 Category Product Description Chassis based 1 0 modules 1756 IF8H 1756 0F8H ControlLogix analog 1 0 modules with the following 1756 IF16H Standard profiles in RSLogix 5000 software DTMs MVI56 HART ProSoft Technology HART multi drop communication interface module for ControlLogix system for use in FactoryTalk AssetCentre Process Device Configuration or other asset management system based on FDT Technology IEC 62453 ISA103 Distributed 1 0 modules 1734 sc IF4H Spectrum Controls analog input module with HART for POINT 1 0 1769 sc IF4IH 1769 sc OF4IH Spectrum Controls analog isolated input and output modules with HART for Compact 1 0 1794 1E8H 1794 OE8H 1794 IF8IH 1794 OF8IH 1797 1E8H 1797 OE8H FLEX analog 1 0 and FLEX Ex analog 1 0 modules with the following Standard profiles in RSLogix 5000 software DTMs Multiplexers gateways EtherNet IP interface Spectrum Controls HART 1 0 with an EtherNet IP interface See the Encompass website for Spectrum product offerings Wireless HART adapter Pepperl Fuchs wireless HART adapter See the Encompass website for Pepperl Fuchs product offerings Network configur
23. Recommendations Architecture Classes Architecture classes define system capabilities that can be scaled by modifying the same system elements Architecture Description System Elements Independent An independent class architecture uses a single computer to perform hosting Single computer serves as the PASS EWS and OWS engineering and operational functions Centralized The centralized system is a multi client configuration that supports the concept of e 1 dedicated PASS see System Elements automating a single production or process area The system elements can provide As many as 5 EWS for the development and maintenance of main control room operation and enable you to mount operator workstations the system locally throughout the production facility The centralized system expands the As many as 8 OWS for the interactive graphical interface independent system by adding workstations and controllers Additional application servers for batch management process information or asset management if applicable Multiple MWS typically laptops Distributed The distributed system is a multi server multi client configuration that supports Each of the four control areas supports these elements automating a process with semi independent areas The distributed class e 1dedicated PASS architecture expands on the centralized class by adding application servers to e Upto three additional AppServ HMI to support additional interconnect multiple pro
24. Reference Manual Allen Bradley PlantPAx Process Automation System System Release 2 0 Process Automation System Rockwell Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGL 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 equipm
25. The engineering workstation EWS supports system configuration application development and maintenance functions This is the central location for monitoring and maintaining the system s operation The following table describes what this chapter contains and where to find specific information Topic Page Controller Recommendations 31 FactoryTalk View Recommendations 38 PlantPAx Library of Process Objects 40 Alarm Implementation Recommendations 41 Application Development Resources 43 This section contains integral information for maximizing your controller and network resources We strongly recommend that you review these topics for system application efficiency Process Controller Configuration Using RSLogix 5000 software configure your controllers and tasks by using the following recommendations Recommendation A task provides scheduling and priority information for a set of one or more programs Place your logic in periodic tasks Create multiple periodic tasks to align with the appropriate scan rate based on the logic it contains For example e Fast 100 250 ms for discrete control such as motors and pumps Medium 250 500 ms for flow and pressure loops or analog inputs Slow 1000 2000 ms for temperature phases batch sequencing Reduce the number of tasks created to improve controller performance Do not use a continuous task See Using Periodic Tasks on page 32 Rockwell Automation P
26. able data and logic memory available for communication The amount of data and logic memory the controller needs varies depending on the state of communication based on the number and type of tags that are accessed by applications such as the HMI and Historian Therefore it s recommended to leave enough data and logic memory capacity to handle the communication When you are offline you can estimate how much controller memory your project requires by using the Memory tab of the Controller Properties dialog box When you are online this tab displays actual memory usage of the controller including memory used for communication e Online you can also view the maximum used memory as communication occurs from this tab 1 See Process Controller Utilization on page 36 for more information See Table 25 on page 69 for more information on controller memory Using Periodic Tasks For PlantPAx system recommendations and sizing tools to work properly the continuous task that is created by default in the RSLogix5000 software should be deleted or changed to a periodic task If left as the default the continuous task runs in the background of the controller as the lowest priority task Any controller CPU time not allocated to other operations or tasks is used to execute the continuous task When the continuous task completes it restarts automatically System overhead time defines the amount of time the controller has available for commun
27. actory Talk Batch software version 11 00 00 requires Factory Talk Services Platform CPR9 SR2 to be on the workstation when it is installed and the other Rockwell Automation Integrated Architecture components in PlantPAx System Release 2 0 require CPR9 SR3 The following is the order that the components should be installed 1 Install all components of FactoryTalk Batch on the Application Server HML Make sure that the Network Directory is selected for control of the batch 2 Install FactoryTalk Batch client components on the PASS AppServ HMI and OWS 3 Install FactoryTalk Batch client and configuration components on the EWS 4 Continue installations with the other integrated architecture components including FactoryTalk View software on the PASS AppServ HMI and OWS FactoryTalk View and RSLogix 5000 software on the EWS The FactoryTalk Batch client components are required on the PASS and AppServ HMI to support replication of batch related objects on the displays to the OWS It is required on the EWS to configure the batch related objects on the displays See Knowledgebase Answer ID 116925 a http rockwellautomation custhelp com for more information on FactoryTalk Batch software version 11 00 00 installation and FactoryTalk Services Platforms Rockwell Automation Publication PROCES RM001F EN P October 2011 Batch Management and Control Recommendations Chapter 6 FactoryTalk Batch In a FactoryTalk Batch applicatio
28. adding spare as a percentage Rockwell Automation Publication PROCES RM001F EN P October 2011 System Element Recommendations Chapter 2 Sizing Control Strategies A control strategy encompasses all of the application code required to implement a specific control function This includes the I O controller code display elements and faceplates Using the control strategy model we are able to estimate the following system parameters e HMI server tags on scan alarm tags display tags data log tags event detector tags and derived tags e Controller memory usage e Controller execution time e Field device variables and health HMI Server Process Information servers collect the process and system data for use in managing the process Operator interface such as graphics and faceplates presents system information to the human operator Controllers execute application code to control the process and communicate with the supervisory level A system is considered working when it is performing at a specified level within established system boundaries By estimating the size of control strategies you have a better prediction of system performance Rockwell Automation Publication PROCES RM001F EN P October 2011 25 Chapter 2 26 System Element Recommendations The amount of resources consumed by the system elements to support a control strategy provides a footprint To size systems these base control
29. an rate increases 2 3 times e Memory use increases 1 1 1 2 times Actual impact to control strategy loading when using redundant controllers can vary depending on the instructions used See the ControlLogix Enhanced Redundancy System User Manual publication 1756 UM535 for more information Process Controller 1 0 Considerations The requested packet interval RPI is a user configured interval of time that determines when an I O module s data is sent to a process controller This interval defines the slowest rate at which 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 Consideration e 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 Use compatible module for keying option on 1 0 cards configuration Rockwell Automation Publication PROCES RM001F EN P October 2011 27 Chapter2 System Element Recommendations Table 10 1 0 Considerations Attribute ControlNet network Consideration Set the network update time NUT equal to or less than t
30. ation Handheld device Endress Hauser handheld configuration and diagnostic device FOUNDATION Fieldbus Recommendations 60 See the Encompass website for Endress Hauser product offerings See the documentation listed in Additional Resources on page 10 for more information The FOUNDATION Fieldbus network is a protocol designed for robust distributed control of process control systems with field devices Follow these guidelines for FOUNDATION Fieldbus networks e The number of devices on an H1 segment depends on the following factors Area and classification Power supply voltage Amount of current each device consumes System update time Resistance of the segment cable e The voltage specification for the H1 segment is 9 32V DC We recommend that you use a 24V DC Fieldbus Foundation power supply and be sure to keep the voltage above 13V DC at the farthest end of the segment e We recommend that you keep the H1 segment below 8 10 devices for maximum performance Rockwell Automation Publication PROCES RM001F EN P October 2011 Field Device Integration Recommendations Chapter 5 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 Typical marcocycles are 500 ms 750 ms 1 s Terminators reduce noise on segments caused by signal reflections at the end of an open cable One terminator on each end of the H1 tr
31. ation Publication PROCES RM001F EN P October 2011 Chapter 5 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 DeviceNet ControlNet FOUNDATION Fieldbus PROFIBUS PA networks or by using HART See http www rockwellautomation com solutions process integrationdocs html for more information on these methods 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 describes what this chapter contains and where to find specific information Topic Page Device Configuration Options 55 EtherNet IP 1 0 Recommendations 56 ControlNet 1 0 Recommendations 57 DeviceNet Recommendations 58 HART Recommendations 59 FOUNDATION Fieldbus Recommendations 60 PROFIBUS PA Recommendations 62 Device Configuration Options There are many options for configuring field devices including the following e Field device vendor tools e Interface directly on the field device e Handheld devices for selec
32. ation Recommendations ControlNet 1 0 Communication Options In a PlantPAx system the ControlNet network supports controller downlinks and connections to remote I O and field device interfaces Table 19 ControlNet Interface Category Product ControlLogix controller interface 1756 CN2 1756 CN2R 1756 CNB 1756 CNBR Description ControlLogix ControlNet scanner 1757 FFLDC2 1757 FFLDC4 ControlNet to FOUNDATION Fieldbus linking device Supports two or four H1 networks Compatible with ControlLogix redundancy and redundant ControlNet media 1788HP CN2PA R ControlNet to PROFIBUS PA linking device from HIPROM Technologies a Rockwell Automation company Supports redundant PA media and redundant ControlNet media See the documentation listed in Additional Resources on page 10 for more information DeviceNet Recommen dations 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 Follow these guidelines for ControlNet networks There is a maximum of 40 nodes on a DeviceNet network Size DeviceNet networks for at least 20 expansion Keep DeviceNet communication modules in the local chassis If the DeviceNet communication module is in a remote chassis set the input and output sizes to match the data configured in RSNetWorx for DeviceNet software
33. ations and servers for example defining the required FactoryTalk Directory you can skip to other sections such as network and field device recommendations Rockwell Automation Publication PROCES RM001F EN P October 2011 9 Preface Additional Resources Table 1 Additional Documentation Resource System Core These documents contain additional information concerning related products from Rockwell Automation Description FactoryTalk View SE Edition User Manual publication VIEWSE UM006 Provides details on how to use this software package for developing and running human machine interface HMI applications that can involve multiple users and servers distributed over a network FactoryTalk View SE Installation Guide publication VIEWSE INO03 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
34. ave space in the local chassis remote chassis on a ControlNet network or remote chassis on an EtherNet IP network for the 1 0 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 1 0 does not depend on change of state data Network topology On a ControlNet network install spare taps so you can add 1756 1 0 modules at runtime without disrupting the network Each tap must be terminated so as to not ground out the system Check the ControlNet system requirements to determine how many spare taps your network can support e Ina ControlNet network with redundant cabling you can break the trunk and add a new tap but redundant cabling is lost during the module installation e Ina 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 of the drop Then re add 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 which communication 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 will need a new
35. bject the instantiated copies reference objects are automatically updated Use of global objects in conjunction with tag structures in ControlLogix can help ensure consistency and save engineering time e When using global objects observe the following recommendations to ensure optimal display call up performance Base global objects are stored in FactoryTalk View in global object displays ggfx files If you have a large number of base global objects defined do not put them all in a single global object display Try to organize your global object displays logically trying to keep an average of 30 base global objects per global object display while minimizing the number of different global object displays referenced by a single standard display Limit the number of global object instances on a single display to 40 or less As global objects may 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 used within the base object e Limit the number of dynamic references on a display to 1 000 references HMI or direct reference tags Be aware that each global object instance may represent multiple references and global objects are allowed to reference other global objects This improves display call up performance Use derived tags for complex expressions or alarm fun
36. by limiting how users can browse the Internet on a computer but can hinder FactoryTalk clients connecting to application servers e Disable Windows error reporting See page 50 Rockwell Automation Publication PROCES RM001F EN P October 2011 49 Chapter 4 50 Infrastructure Recommendations Disable Windows Error Reporting There is an error reporting feature included with most versions of Windows that can be used to report computer and program errors to Microsoft However disabling this feature will free up computer resources since Microsoft currently does not forward any error information to Rockwell Automation We recommend that this feature be disabled on PlantPAx servers and workstations Do these steps to disable error reporting on an individual computer 1 To open the System Properties dialog box choose Start Setting Control Panel System 2 On the System Properties dialog box select the Advanced tab and click the Error Reporting button The Error Reporting dialog box displays 3 Select the default Disable error reporting option If you don t want to see any type of error message clear the But Notify Me When Critical Errors Occur check box 4 Click OK twice To disable Error Reporting on multiple computers in a Windows domain environment use the Group Policy Editor for the domain The policy settings are located in Computer Configuration Administrative Templates System Error Reporting When you config
37. cation PROCES SG001 Provides an overview of the three typical process architectures independent centralized and distributed 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 Ethernet to the Factory 1 2 Design and Implementation Guide publication ENET TD001 Provides collaborative design guidelines based on the Cisco Ethernet to the Factory solution and the Rockwell Automation Integrated Architecture solution Stratix 8000 and 8300 Ethernet Managed Switches Software User Manual publication 1783 UM003 Details how to configure and maintain managed switches ControlNet Coax Media Planning and Installation Guide publication CNET INOO2 ControlNet Fiber Media Planning and Installation Guide publication CNET IN001 ControlNet Modules in Logix5000 Control Systems User Manual publication CNET UM001 Provides procedures for planning installing and implementing a ControlNet network Field Device Integration FactoryTalk AssetCentre Installation Guide publication FTAC IN004 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 informatio
38. ce co oo 57 ControlNet I O Communication Options 006 58 DeviceNet Recommendations cccccececccceeveceeenens 58 DeviceNet Communication Options 0 e cee eee eens 59 HART Recommendations sa cnakuukeeeAnaGa det etunternatwatanatan 59 HART Communication Options 0 0c cece eee eee 60 FOUNDATION Fieldbus Recommendations o oooooomommm 60 FOUNDATION Fieldbus Communication Options 61 PROFIBUS PA Recommendations 00 0 cc eee ee cence eens 62 PROFIBUS PA Communication Options 000005 62 Chapter 6 FactoryTalk Batch Critical System Attributes oooooooooo 63 Install Factory Talk Batch Client Components ooooccccoccccco 64 Factory Talk Batch Application Guidelines o ooooooommmmoo 65 Batch Guidelines for Logix iii 65 Rockwell Automation Publication PROCES RM001F EN P October 2011 Maintenance Recommendations Glossary Index Table of Contents Chapter 7 Maintaining Your Sa oa ty 67 Microsoft Updates sare ite ste uted uid th hare isis 67 Antivirus Software 0 e cece cece cece cece eeecenaaenaes 68 Rockwell Automation Software Firmware Updates 68 Considerations when Upgrading Software and Firmware 69 Monitoring Your System sprite 69 Check Paging Utilization tra 71 Additional Monitoring Resources 0 00 s cece cece eee eee 71 Services and SOppO rana se bedevtey epetateaseess 72 Site P
39. ces Platform FTSP is a service oriented architecture see SOA that delivers value through FactoryTalk enabled products This platform reduces the customer learning curve and project engineering time through commonality and reuse For example activation FactoryTalk Directory security diagnostics audit live data and alarms and events An object that is created once and can be referenced multiple times on multiple displays in an application An historian is a data collection system with the following components collection storage compression retrieval reports and analysis Historian functions include raw sampling compression storage retrieval reconstitute analyze summarize and present reports and displays Historical data is data that is used for the long term analysis of past operation Historical data is typically retrieved Integrated Architecture IA is the identifying name of Rockwell Automation group of products that use Rockwell Automation core enabling technologies The PlantPAx Process Automation System is a defined set of A products configured in a prescribed way to provide optimal performance as a process automation system Rockwell Automation Publication PROCES RM001F EN P October 2011 operator workstation OWS PlantPAx Process Automation System Process Automation System Server PASS RSLinx software server system attribute system element system infrastructure system server User
40. cess areas into a system processing areas and clients A distributed system can have up to four control areas As many as 5 EWS As many as 8 OWS per PASS or AppServ HMI Additional application servers for batch management process information or asset management if applicable The diagram shows an example of PlantPAx system architecture utilizing the EtherNet IP network This example could be a centralized or distributed architecture class Application Servers Multiple OWS Domain EWS PASS Controller Device level Ring Topology 14 Rockwell Automation Publication PROCES RM001F EN P October 2011 System Elements System Architecture Recommendations Chapter 1 System elements are specific IA products grouped to provide process system functionality System Element Independent Class Centralized Class Distributed Class Process automation system Single computer serves as PASS EWS and OWS One PASS required and includes One PASS required and includes server PASS in an independent workstation FactoryTalk Directory server FactoryTalk Directory server HMI server HMI server Data server Data server Engineering workstation Included in independent workstation e 1 EWS required e 1 EWS required EWS Can have as many as 5 EWS e Can have as many as 5 EWS Operator workstation OWS Included in independent workstation 8 remote clients 8 remote clients for PASS 8 addit
41. chassis with digital modules in the future configure the network and add it to the 1 0 configuration tree as rack optimized Then inhibit the communication adapter until you need the chassis Network performance You can add 1 0 modules at runtime until you impact the capacity of the communication module Make sure you have sufficient communication modules for the connections you plan to add See the Logix5000 Controllers Design Considerations Reference Manual publication 1756 RM094 for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 29 Chapter2 System Element Recommendations AppServ HMI Software Component FactoryTalk View HMI server Use these guidelines when gauging whether to implement an additional AppServ HMI for your PlantPAx system e When you have more than one type of data server such as RSLinx Enterprise or OPC data servers e When you want to balance the load you are at gt 40 CPU of your PASS or existing AppServ HMI e For creating logical area for example you want to perform routine maintenance on a server for one area without affecting other areas The AppServ HMI includes the following Rockwell Automation Integrated Architecture software components Description The HMI server stores HMI project components such as graphic displays and serves these components to Operator Workstations upon request The HMI server also can manage tag databases and log
42. controllers from the CompactLogix family for skid based or small local applications Product CompactLogix 1769 L23E or 1769 L35E controller Attribute CompactLogix 1769 L23E CompactLogix 1769 L35E User memory 0 5 MB 1 5 MB Total 1 0 recommended max 80 250 Total tags max 4000 12 800 Recommended control strategies max 10 30 Total control strategies 250 ms max 10 30 Total control strategies 500 ms max 10 30 Tags sec delivered to data server max 3000 3000 1 These values are maximum limits You may not be able to achieve all of these in a single controller 2 Representative control strategy PID loop includes 1 analog input 1 analog output 1 PIDE instruction 8 logic math instructions and up to 8 configured alarms with PlantPAx process objects and Native instructions 3 Assumes RSLinx Enterprise software version 5 30 00 at 10 K sec per instance 22 Rockwell Automation Publication PROCES RM001F EN P October 2011 System Element Recommendations Chapter 2 Table 7 Redundant Controller Hardware Hardware Process controller Redundant Controllers ControlLogix controllers support enhanced redundancy on ControlNet and EtherNet IP networks Product ControlLogix 1756 L63 controller ControlLogix 1756 L73 1756 L74 or 1756 L75 controller Do not combine 1756 L6x and 1756 L7x controllers in a redundant chassis Redundancy module e 1756 RM Controller
43. ctions that are repeatedly used within graphic displays for example alarm expressions This reduces HMI server load 38 Rockwell Automation Publication PROCES RM001F EN P October 2011 Data ing Load Periodic Data Logging Log files cut every hour Log files kept for 10 days System Application Recommendations Chapter 3 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 if VBA is performing badly the entire HMI can perform badly Data Log Recommendations Data logging uses the FactoryTalk View SE application data log capability and should be used for only short term data retention typically less than a 24 hour period Data is stored on the PASS or AppServ HMI of operator defined process variables to aid in controlling the process Data logging is for storing a minimal number of data for example no more than 50 data log points per controller For long term data storage or to collect a large number of data points use the FactoryTalk Historian software Configure data logging to the following p a Log to a separate drive from the system drive for example file set absolute path is D Logfiles Delete oldest file after 10 days to conserve disk space if necessary Set logging to periodic for a consistent system load Set to logging to on change for infrequently changing da
44. d select Explore 2 On the Tools menu select Folder Options The Folder Options dialog box appears 3 In the View tab under Advanced settings clear the Use simple file sharing check box Do these steps to turn off fast user switching in Windows XP 1 Open the Windows Control Panel and double click User Accounts 2 Click the Change the way Users Log on and Offlink 3 Clear the Use Fast User Switching check box 4 Click Apply Options Internet Information Server IIS The Internet Information Server IIS provides graphics displays and other file based components from the HMI server on the PASS or AppServ HMI to OWS and EWS workstations by using Web based Distributed Authoring and Visioning WebDAV WebDAV is an extension to the HTTP protocol that facilitates editing and managing files across multiple users and workstations In addition when OWS and EWS workstations issue FactoryTalk View commands that must be run on the HMI server the commands are sent by using the IIS platform Therefore the IIS software is a required component on the PASS and AppServ HMI servers We recommend against the installation of IIS on any other system elements See Chapter 2 of the FactoryTalk View Site Edition Installation Guide publication VIEWSE IN003 for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 47 Chapter 4 48 Infrastructure Recommendations Dornain Controller Serv
45. d States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PROCES RM001F EN P October 2011 Supersedes Publication PROCES RM001E EN P January 2010 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in the U S A
46. d and transferring it to virtual memory to free up memory for active processing tasks But this process of moving pages of data back and forth between memory and virtual memory can slow down a system Generate an alert if Paging Utilization exceeds 90 percent See Check Paging Utilization on page 71 for details Controller CPU Utilization L_CPU Free CPU time is required to handle communications or abnormal conditions and other transient loads RSLogix 5000 Controller Properties e Outside of production environment before connecting FactoryTalk View and Historian clients recommend or 50 free CPU time RSLogix 5000 Task Monitor When in production environment while FactortTalk View and Historian are connected recommend 25 free CPU time We don t recommend using a continuous task However if one is used it is import that system overhead time slice is set to allow for 25 space CPU capacity under normal loading Controller Memory Utilization L_CPU For simplex controllers follow these guidelines or Outside of production environment before connecting FactoryTalk View Predefined FactoryTalk View and Historian clients we recommend A 50 free memory to support communications and RSLogix 5000 Controller handling of abnormal conditions When in production environment while FactoryTalk View and Historian are connected we recommend 30 free memory to support handling of abnormal conditions Maintain greater than 50
47. data and 1 0 memory Each controller in the redundancy chassis has enough memory to store twice the amount of controller data and 1 0 memory The increase of memory usage provides for a bumpless transfer during a switchover to make sure the secondary Logix controller has the same values in its output image as the primary Logix controller This prevents a switchover to a secondary controller with a mixture of old and new data memory See Understand ControlLogix Redundancy Memory Usage in Knowledgebase Answer ID 28972 at http rockwellautomation custhelp com for more information You must have a Rockwell Automation support agreement Redundant EtherNet IP network A redundant Ethernet network is based on architecture topology and requires multiple Ethernet interfaces 1756 EN2T 1756 EN2TR B 1756 EN3TR Redundant ControlNet network A redundant ControlNet network requires a ControlNet interface that supports redundant media 1756 CN2R or 1756 CN2RXT Identical ControlNet modules are placed in the same slot of both chassis of the redundant pair ControlNet modules are identical in redundancy firmware revision and in series 1 If environmental conditions warrant you can use an extreme temperature controller for example the 1756 L74XT Table 8 Redundant ControlLogix Controller Sizing Attribute 1756 163 1756 L73 1756 L74 1756 L75 User memory 8 MB 8 MB 16 MB 32 MB Total 1 0 rec
48. dit the Add On Instruction definition To protect intellectual property routines and local tags can also be hidden on protected Add On Instructions if desired The use of Add On Instructions can save time by creating sets of commonly used instructions They 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 data and time so that revisions of Add On Instructions can be managed between projects Add On Instructions can be used to create device level instructions like a valve controller or standard calculation where each instance is configured but the source definition is unlikely to change Like a native instruction the definition of an Add On Instruction cannot be modified online Therefore it s important that you fully test all configuration options before implementing an Add On Instruction on your production system The PlantPAx Library of Process Objects uses Add On Instructions See page 40 for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 35 Chapter 3 36 System Application Recommendations Process Controller Utilization Free Process controller CPU time is required to handle communications abnormal conditions and other transient loads Therefore it s important to consider CPU utilization when implementing the application code When defining the app
49. dministration throughout the PlantPAx system In this way 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 See Set Up the FactoryTalk Directory on page 19 for more information FactoryTalk Activation server FactoryTalk Activation is part of the FactoryTalk Services Platform It allows FactoryTalk enabled products to be activated via files generated by Rockwell Automation over the internet This server essentially manages the files required to license Rockwell Automation products on the PlantPAx system FactoryTalk View HMI server The human machine interface HMI servers are configured within your FactoryTalk View Site Edition SE application It stores HMI project components such as graphic displays and serves these components to Operator Workstations OWS upon request The HMI server also can manage tag databases and log historical data Multiple HMI servers can exist on the PlantPAx system See AppServ HMI on page 30 for more information FactoryTalk View Data server The Data server component provides access to information from the process controllers to the HMI server and OWS station FactoryTalk View supports two types of data servers Rockwell Automation Device servers RSLinx Enterprise and OPC Data servers The Data server mentioned in PlantPAx documentation generally refe
50. egrated Architecture IA 74 A critical system attribute CSA is a customer facing characteristic that defines or identifies whether the system is performing as expected CSAs are specific visible indicators of overall system performance and usability CSAs have specified parameters that must be maintained and that set the base operational requirements for the system These parameters determine pass or fail follow up ofa system test For example screen paint time lt 2 seconds and screen refresh lt 1 second There are many other attributes associated with system elements such as controller loading computer loading and network settings that must be configured properly in order to maintain system CSAs Development software is a program that is used to configure various system components and not required at runtime For example RSLogix 5000 software and FactoryTalk View software A display object is a functional group of display elements with animations The engineering workstation EWS provides system configuration development and maintenance functions of the PlantPAx system The EWS contains development software including FactoryTalk View SE Studio and RSLogix 5000 software FactoryTalk Directory software defines were system data is located to allow for quicker access FactoryTalk Directory software provides a common address book of factory resources that are shared among FactoryTalk enabled products The FactoryTalk Servi
51. ent or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence 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 PP ee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation PlantPAx Process Automation System ControlLogix CompactLogix FactoryTalk Directory FactoryTalk Historian FactoryTalk AssetCentre FactoryTalk View ME FactoryTalk View SE FactoryTalk View Studio FactoryTalk Services Platform FactoryTalk Activation FactoryTalk Alar
52. er ID 62682 at http rockwellautomation custhelp com Rockwell Automation Publication PROCES RM001F EN P October 2011 37 Chapter3 System Application Recommendations FactoryTalk View For implementing FactoryTalk View SE software for a process system operator Recommendations interface follow these guidelines e Run FactoryTalk View Studio software on the EWS during runtime Do not run FactoryTalk View Studio software on the server PASS or AppServ HMI during runtime operation e Set the FactoryTalk View SE servers to start automatically on start up on the AppServ HMI and PASS Let the servers fully start up before starting the client computers e Do not run remote desktop clients on the AppServ HMI or PASS e Do not use the remote desktop for system development e Any Area contains only 1 server of any type HMI or Data This will prevent the failure of one data server from affecting any others that are in the same area This will also prevent potential performance problems e Minimize the number of areas accessed on one display e 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 AOI 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 o
53. er 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 may occur 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 Window Time Services from Domain Controller OWS Logix5000 Clock Tool running on the PASS 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 Rockwell Automation Publication PROCES RM001F EN P October 2011 Infrastructure Recommendations Chapter 4 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 lt target gt period lt refresh gt dataonly Parameter Identifies computer lt target gt The computer to measure the offset against period lt refresh gt The time bet
54. es including flow transmitters and drives are available that support TCP IP EtherNet IP 1 0 Communication Options e Configure all communication cards to operate at 100 MB full duplex do not use auto negotiate e Disable keying on Ethernet communication modules e You cannot bridge EtherNet IP I O modules across networks I O modules have to be in either a local or remote chassis not bridged through backplanes Product Description 1756 EN2T 1756 EN2TR 1756 EN2F ControlLogix EtherNet IP scanner 1756 ENBT 1756 EWEB 1757 FFLD2 EtherNet IP to FOUNDATION Fieldbus linking device Supports two or four H1 1757 FFLD4 FOUNDATION Fieldbus networks 1788HP EN2PA R EtherNet IP to PROFIBUS PA linking device from HIPROM Technologies a Rockwell Automation company Supports redundant PA media and DLR capable Ethernet See the documentation listed in Additional Resources on page 10 for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 ControlNet 1 0 Recommendations Setting ControlNet 1 0 Field Device Integration Recommendations Chapter 5 The ControlNet network is an open control network for real time high throughput applications The ControlNet network combines the functionality ofan I O network and a peer to peer network providing high speed performance for both functions Details Maximum 5 controllers can have a rack optimized listen only connection to the module 64
55. forests have individual functional levels We recommend configuring at least two domain controllers in the domain These domain controllers will replicate automatically to provide high availability and an online configuration backup Add the PASS as a member of the domain before developing your FactoryTalk View application The domain servers also must be configured to include Domain Name Service DNS which lets you identify devices by name rather than IP addresses Configure time synchronization throughout a domain New and existing active directory domains should have operations verified by using Microsoft s Domain Controller Diagnostics Dcdiag exe utility This utility is included with the Windows support tools on the operating system CD and can also be downloaded from Microsoft IMPORTANT Donot install the Windows domain controller on the PlantPAx PASS server or application servers Rockwell Automation Publication PROCES RM001F EN P October 2011 Infrastructure Recommendations Chapter 4 Windows Workgroup Recommendations PlantPAx can use a Windows workgroup network environment for systems using 10 or fewer computers However if you are using a Windows XP operating system you must turn off simple file sharing and fast user switching on each PlantPAx server and workstation in the workgroup Do these steps to turn off simple file sharing in Windows XP 1 On the desktop or in Windows Explorer right click My Computer an
56. formation See the Knowledgebase Answer ID 62682 at http rockwellautomation custhelp com FactoryTalk Diagnostic sample displays Sample graphics to display RSLinx Enterprise 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 current Status and state by using VBA and displaying the status on the HMI screen See the Knowledgebase Answer ID 44624 at http rockwellautomation custhelp com PlantPAx Preferred Integration tools Add On Instructions and pre defined faceplates for Endress Hauser field devices See the Knowledgebase Answer ID 60185 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 FactoryTalk Batch implementation tools Batch tools for collecting organizing reporting and visualizing FactoryTalk View data See the following Knowledgebase Answer IDs at http
57. function or role A system element can be manipulated to vary system operation or capability For example engineering workstation EWS operator workstation OWS process automation system server PASS controller unit chassis power supply controller an I O unit chassis power supply module System infrastructure is the commercial off the shelf hardware and software required to enable system elements to work together as a system For example network switches computers and so forth A system server expands the scope of a system by providing support for additional system capacity or optional system functions For example the Process Automation System Server PASS is a required component for all centralized and distributed process systems The PASS provides central name resolution and system wide FactoryTalk services The PASS provides the capability to distribute information to the OWS and add to optional application servers to increase the scope of the process system Tags that you create once and reuse in multiple templates multiple times A workstation is a computer running development configuration and optionally maintenance software A workstation is not a server Rockwell Automation Publication PROCES RM001F EN P October 2011 75 Glossary Notes 76 Rockwell Automation Publication PROCES RM001F EN P October 2011 A activation FactoryTalk 18 adapters Ethernet 1 0 53 additional resources 10 Add On Instruc
58. ges e Includes complete set of visualization components No support for PanelView Plus platform FactoryTalk Alarm summary Alarm banner Alarm Status Explorer View ME and so forth Lower number of supported alarms per system 20 000 and alarms and attached clients per system 20 OWS Native ability to log alarm history to SOL database Logs alarm in UTC time FactoryTalk Alarms and Events FTAE supports device based alarms ALMA and ALMD instructions in the controller and server based alarms level discrete or deviation alarms FTAE device based and server based alarms can co exist in a single application For your PlantPAx system we recommend that you use FTAE server based alarms Use device based alarms for only the most critical or time critical alarms HMI Classic Alarm Recommendations e Only use HMI Classic Alarms if your application doesn t support the use of FactoryTalk Alarms and Events e Use alarm handshaking only for critical alarms to reduce the number of tags that must be held on scan in large applications e When making changes to the HMI tag database related to alarming run the AlarmAcceptEdits command to make effective all alarm changes made since the last AlarmOn command When using redundant HMI servers AlarmAcceptEdits may cause the alarm synchronization between the primary and secondary server to stop because the configuration in the primary and secondary servers no longer match To address
59. h as FactoryTalk Batch FactoryTalk Historian or FactoryTalk AssetCentre 20 Rockwell Automation Publication PROCES RM001F EN P October 2011 Process Controller Table 3 Simplex Controller Hardware Hardware Process controller System Element Recommendations Chapter 2 This section describes the components and sizing attributes for simplex skid based and redundant controllers Simplex Controller Simplex controller hardware components are the ControlLogix family of products in a non redundant configuration Product ControlLogix 1756 L61 1756 L62 or 1756 L63 controller ControlLogix 1756 L72 1756 L73 or 1756 L74 controller EtherNet IP interface 1756 EN2TR B 1756 EN3TR 1783 ETAP supports device level ring topology e 1756 EN2T 1756 ENBT 1756 EWEB 1756 EN2F 1783 ETAP1F 1783 ETAP2F The fiber 1783 ETAP modules support device level ring topology ControlNet interface e 1756 CN2 1756 CN2R e 1756 CNB 1756 CNBR 1 If environmental conditions warrant you can use an extreme temperature controller for example the 1756 L74XT Table 4 Simplex ControlLogix Controller Sizing Attribute 1756 L61 1756 L62 1756 L63 1756 L72 1756 L73 1756 L74 1756 L75 User memory 2MB 4MB 8MB 4MB 8 MB 16 MB 32 MB Total 0 recommended max 375 750 1500 750 1500 2250 2250 Total tags max 15 625 31 250 62 500 31 250 62 500 112 500 112 500 Recommended control
60. he fastest RPI of the 1 0 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 All 1 0 should be unscheduled to be able to add ControlNet modules at runtime See 1 0 Module Runtime Online Considerations Dedicate one ControlNet network to 1 0 communication only Unscheduled 1 0 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 1 0 network make sure of the following No HMI traffic No MSGtraffic No programming workstations No peer to peer interlocking in a multi processor system architecture EtherNet IP network See Chapter 4 for infrastructure recommendations 1 0 Module Runtime Online Considerations With the PlantPAx system you can add modules to the Controller Organizer in RSLogix 5000 software when the controller is in Run mode e You can add the 1756 I O modules to the local chassis remotely via the unscheduled portion of a ControlNet network and remotely via an EtherNet IP network e You can add the 1757 FFLDC linking device remotely to the unscheduled portion of a ControlNet network and the 1757 FFLD linking device remotely via an E
61. ication and interrupts the continuous task for communicating to HMI devices processing MSG instructions and alarm instruction processing Continuous task is very good for high speed discrete applications where the main goal is to execute code as fast as possible We recommend not using the continuous task on the PlantPAx system for the following reasons e Time based operations such as a PID algorithm do not function accurately when run in a continuous task e Removal of the continuous task improves predictability of the controller free time available for communication to the system e Removal of the continuous task allows for a more accurate view of the controller loading at run time With continuous task controller loading is always 100 e Removal of the continuous task reduces the amount of task switching that improves overall application and system performance 32 Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 14 Process Controller Recommendations Attribute Tags System Application Recommendations Chapter 3 Controller Project Considerations Configure the tasks in the process controller by using the following recommendations Recommendation See Controller Tag Optimization Add On Instructions See Using Add On Instructions on page 35 Produced and consumed tags A single produced and consumed tag can contain multiple combinations of data For example up to 120 REALs
62. iles W3SVC1 but the actual location can be determined from the Internet Information Server Manager IIS Logs Look for return codes 400 404 or 500 503 IIS Troubleshooting HTTP error codes See the Knowledgebase Answer ID 39618 at http rockwellautomation custhelp com Rockwell Automation Publication PROCES RM001F EN P October 2011 69 Chapter7 Maintenance Recommendations Table 25 PlantPAx System Monitoring Recommendations System Attribute Server and Workstation CPU Utilization How To Monitor Windows Administration Tool PerfMon Performance Monitor See Knowledgebase Answer ID 31196 at http rockwellautomation custhelp com Description The CPU utilization for the PASS App Servers and OWS computers should be 40 or less during steady state operation In PerfMon CPU Utilization is lt Computer Name gt Processor_Total Processor Time Server Paging File Utilization Windows Administration Tool PerfMon Performance Monitor See Knowledgebase Answer ID 31196 at http rockwellautomation custhelp com Windows Alerter and Messenger services See Knowledgebase Answer ID 64958 at http rockwellautomation custhelp com Paging File Utilization can be found in the Microsoft Performance Monitor tool but monitoring lt ComputerName gt Paging File C pagefile sys Usage Paging is the process of locating a page of data in physical memory that is currently not being use
63. in a single PlantPAx system must be members of the same workgroup All users participating 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 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 should not be used as domain controllers Required for systems with more than 10 computers The domain controller should be its own independent computer with no other application software Rockwell Automation Publication PROCES RM001F EN P October 2011 45 Chapter 4 46 Infrastructure Recommendations Domain Recommendations We recommend that all PlantPAx system servers and workstations be a member of adomain Follow these additional recommendations Windows Active Directory AD domains include the concept of a forest which can consist of a single domain tree or multiple domain trees TIP A domain tree can consist of a single parent domain or multiple child domains A single forest single tree single domain configuration is recommended In a Windows 2008 Active Directory both domains and
64. ional remote clients per AppServ HMI Process controller 1335 ControlLogix controllers 1 6 ControlLogix controllers per PASS 1 6 ControlLogix controllers per AppServ HMI 1 6 ControlLogix controllers Application servers None One AppServ Batch for each set of six controllers One AppServ Information Management One AppServ Batch One AppServ Information Management 1 Controller count based on fully loaded L63 controllers Actual controller count allowed may vary based on controller selection and loading Critical System Attributes Table 2 CSA Performance Indicators Critical System Attribute Display callup paint time A critical system attribute CSA is a visible performance indicator of a system wide characteristic to define or identify if a system is working at a specified level CSAs are pass fail attributes Critical system attributes do the following e Determine system limits e Establish system rules e Establish system recommendations e Measure system element and system infrastructure performance The following critical system attributes were used to verify performance during process system characterization Performance Anoncached 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 times
65. ions 42 Factory Talk Device based Alarm Recommendations 42 Using the PlantPAx Library of Process Objects for Alarms 43 Application Development Resources oooocooccrorccnrccnccnooo 43 Rockwell Automation Publication PROCES RM001F EN P October 2011 5 Table of Contents Infrastructure Recommendations Field Device Integration Recommendations Batch Management and Control Recommendations Chapter 4 Operating System Recommendations 000 cece ee eens 45 Domains and Worker Sra pi ia 45 Domain Recommendations 0ccecucccseccaveecceeens 46 Windows Workgroup Recommendations 00000 47 Internet Information Server IIS ccececeecececeeceees 47 Server and Workstation Time Synchronization 48 Operating System Optimization dys teva dn tos Regimens 49 Disable Windows Error Reporting 00sec cece cece ee 50 Virtualization A O aa aS 50 Network Recommendations 0ccccececcccecucveceeenens 51 Ethernet Switches be Manca tect otaoa we bed Ga eee a 52 Controller and I O Ethernet Adapters wco 0220s0es neces dacanen 53 Chapter 5 Device Configuration Options minis ewan eer aw nets 55 FactoryTalk AssetCentre for Enterprise Solution 56 EtherNet IP I O Recommendations 0c0cceceececeeeeees 56 EtherNet IP I O Communication Options 0 56 ControlNet I O Recommendations 0 0c cece cece ce
66. ips A characterization is the operation and collection of performance data for a representative process system to determine scalability stability and usability of a specific system configuration A characterization is the following e Aimed at defining a complete system e Used to determine if the system is performing at specified level e Used to identify usability issues e Used to check and create rules relationships limits and recommendations for system elements A client is hardware personal computer and software that provides an interface with a link into a system server application In the Rockwell Automation architecture a client is a computer loaded with runtime software A control strategy is a system footprint to show the complexity of the following e Data servers e Information storage e Operator interface graphics faceplates e Control code sequence procedure phases I O Control strategies are used to determine a set of comprehensive process system footprints that establish a representative system loading that can be measured to identify a process system s boundaries and limitations implementation rules Rockwell Automation Publication PROCES RM001F EN P October 2011 73 Glossary critical system attribute CSA development software display object engineering workstation EWS FactoryTalk directory software FactoryTalk services platform global object historian historical data Int
67. k but not less than 2 ms e Always set the input and output words in the local chassis to the maximum number when adding the DeviceNet scanner to the I O tree to allow for online expansion in the future e Use Background poll when possible e Keep Foreground to Background Poll Ratio Interscan Delay gt 75 ms e Instead of Automapping you can DINT align data and map to the multiplier of node address Node Address 2 Local 2 I Data 6 0 DeviceNet Communication Options In a PlantPAx system the DeviceNet network connects networked control devices Category Description ControlLogix controller interface 1756 DNB ControlLogix DeviceNet scanner See the documentation listed in Additional Resources on page 10 for more information HART Recommendations HART is an open protocol designed to provide digital data over 4 20 mA analog signals Follow these guidelines for connectivity to a HART I O card e Only enable HART data on the channels that are capable of receiving HART data e Data updates are dependent on the number of channels enabled and the interface card used for example if there are shared modems or dedicated modems for each channel e Ifusing HART data for control check the data quality bits e For controlling fast loops use only the 4 20 mA output of the instrument for control instead of the extended HART data Rockwell Automation Publication PROCES RM001F EN P October 2011 59 Chapter5
68. lement 15 LBSM 63 load 36 memory 32 project considerations 33 properties advanced 32 simplex 21 skid based 22 tags 33 optimization 33 count controllers 15 1 0 determination 24 CPU utilization 36 Rockwell Automation Publication PROCES RM001F EN P October 2011 17 Index 78 critical system attribute 15 63 definition 74 D data log loading 39 server FactoryTalk 18 definition infrastructure 45 PlantPAx 9 description Add On Instruction 35 EWS 20 OWS 20 PASS 18 development software definition 74 device based alarms 42 directory FactoryTalk 18 location utility 19 display object definition 74 distributed architecture 14 documentation batch 11 field devices 10 infrastructure 10 system core 10 domain and workgroup recommendations 45 element application server 15 EWS 15 overview 17 OWS 15 PASS 15 process controller 15 recommendations 17 system 15 engineering workstation definition 74 equipment phases batch 65 error reporting 50 Ethernet 1 0 adapters 53 switches 52 EWS description 20 element 15 software 20 example control strategy 26 data log loading 39 loading 27 F FactoryTalk activation server 18 alarm recommendations 42 alarms and events server 18 batch server 18 data server 18 device based alarms 42 directory configuration 19 directory server 18 directory software definition 74 HMI server 18 recommendations 38 server based alarms 42 services platf
69. lication code make sure the CPU utilization of the process controller can accommodate these values e Inthe development environment CPU utilization should be less than 50 to allow for the additional CPU load that will be experienced in the production environment During the operation of the system the CPU utilization should be monitored especially after a change to the application code and should never exceed 75 e During the design of the application code it is important to account for software components such as FactoryTalk View or Historian that are actively collecting data from the controller to make sure CPU utilization is less than 75 to allow for communication with the supervisory system elements EWS OWS Information server There are two options for reviewing controller loading e Task Monitor Available from RSLogix 5000 software on the EWS e L_CPU Add On Instruction Preferred method of monitoring viewable from HMI screens and available from the Knowledgebase Answer ID 62682 at http rockwellautomation custhelp com Task Monitor If your process controller contains periodic tasks only see page 32 use the RSLogix 5000 Task Monitor tool 5 Logix5000 Task Monitor PlantPAxDemo 1756 163 Communicatons Options Help User Tasks Prozesses Performance Networking EherNet 1P EtherNet IP Controles Controller EB UP Reactor 01 100 00005 068 10 3376us 36 8 500008 0 QRUP Reacto
70. lication 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 AppServ HMI Redundancy All the Application Server HMI software components can be made redundant through the server properties dialog box with the FactoryTalk View application When enabling redundancy in FactoryTalk View Studio select the option to Continue using the secondary server when the primary server becomes available again to avoid excessive switchovers and to be able to manage replication of application changes made before or after the switchover occurs Follow these guidelines for redundant HMI servers e Avoid implementing HMI server redundancy until system testing or commissioning e Initially HMI server files should be copied from the primary to the secondary server The Replication button can be used after initial copy e Alarm states are synchronized between HMI servers during runtime automatically Rockwell Automation Publication PROCES RM001F EN P October 2011 Controller Recommendations Table 13 Controller and Task Recommendations Attribute Tasks Chapter 3 System Application Recommendations After initial installation of the system elements there are system application recommendations to follow when creating application specific code These recommendations help to make sure of optimal performance of the PlantPAx system
71. modified from the original deployment You can use library objects other than the PlantPAx collection For example you can choose to develop your own library or use the PlantPAx elements and faceplates as guides Using a library of consistent elements will improve the maintainability and efficiency of your PlantPAx system 40 Rockwell Automation Publication PROCES RM001F EN P October 2011 Alarm Implementation Recommendations Table 15 Alarm Options Alarm Options HMI Classic Alarming System Application Recommendations Chapter 3 PlantPAx offers two options for configuring alarms HMI classic alarming and FactoryTalk Alarm and Events Description Using FactoryTalk View you would configure alarms as a property of a HMI tag in the HMI server Advantages e Only architecture supported for FactoryTalk View ME PanelView Plus e Support for a high number of alarms 40 000 per HMI server of which 10 000 can be Disadvantages e Limited visualization objects Limited alarm logging functionality Logs alarm in local time as configured in the HMI server analog tags FactoryTalk Alarms and Events Alarms can be configured in the controller or in a FactoryTalk View server Device based alarms ALMA ALMD are subscribed to by the RSLinx Enterprise server when the option is enabled Server based alarms digital level or deviation are configured in a tag Alarm and Event server Advantages Disadvanta
72. ms and Events FactoryTalk Batch CENTERLINE PanelView Plus RSLinx Classic RSLinx Enterprise Logix5000 RSLogix 5000 RSNetWorx for ControlNet RSNetWorx for DeviceNet FLEX Ex FLEX I O PhaseManager RSView SE Client RSView Studio ControlFLASH and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies New and Updated Information Summary of Changes This manual revision concentrates on the implementation recommendations that apply to all PlantPAx systems Information not specific to the PlantPAx system or focused on system procurement was removed This table contains some of the changes made to this revision Topic Page Core control components have been split into two sections System Element Recommendations 17 System Application Recommendations 31 Chapter 7 Maintenance Recommendations has been added to assist with 67 maintaining and monitoring your PlantPAx system Rockwell Automation Publication PROCES RM001F EN P October 2011 Summary of Changes Notes 4 Rockwell Automation Publication PROCES RM001F EN P October 2011 Preface System Architecture Recommendations System Element Recommendations System Application Recommendations Table of Contents Additional Resources dt O ei 10 Chapter 1 a A O EERE 14 System Blemients s uren aa E cae ae Sees eed 15 Critical System Attributes pers Ti a 15 System P
73. n across your entire enterprise 10 Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 1 Additional Documentation Resource 1756 ControlLogix Communication Modules Specifications Technical Data publication 1756 TD003 Preface Description Contains specifications for the ControlLogix network communication modules Ethernet Design Considerations Reference Manual publication ENET RM002 Explains the infrastructure and components for the EtherNet IP protocol a control and information platform for industrial environments and time critical applications EtherNet IP Modules in Logix5000 Control Systems User Manual publication ENET UM001 Explains Logix5000 tools that are used in EtherNet IP topologies and network operation FOUNDATION Fieldbus System User Manual publication 1757 UM012 FOUNDATION Fieldbus Design Considerations Reference Manual publication RSFBUS RM001 FOUNDATION Fieldbus Linking Device Technical Data publication 1757 TD003 Publications provide design configuration and specifications for fieldbus devices and the 1757 FFLD and 1757 FFLDC linking devices ControlLogix HART Analog 1 0 Modules User Manual publication 1756 UM533 Contains information on how to install configure and troubleshoot ControlLogix HART analog 1 0 modules Promass 83 Flowmeter via PROFIBUS PA to the PlantPAx Process Automation System publication PROCES AP022 Provides procedures f
74. n follow these guidelines Application Guidelines The naming of batch phases exactly matches the phase name in the controller For example AREA01_PC1_PM_EP_AddA is a phase name Automatic uploads and downloads satisfy most needs There still are situations where custom code is necessary to request parameters and upload reports Some phases use the transfer of control feature to change recipe parameters dynamically The ControlLogix phase manager logic requests parameters manually using the controller PXRQ instruction Batch Guidelines for Logix Use PhaseManager to develop the equipment phases in the Logix controller The following guidelines for configuring phases apply for both FactoryTalk Batch and LBSM All phase names in all of the controllers must have a unique name In each phase the running routine should keep track of 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 which step the running SFC was in when the phase received the Hold command and on what actions the Holding state routine took with the equipment controlled Ifa timer runs across many phase state routines for example a phase that runs an agitator that does not stop when Held but you must keep track of the time that the agitator ran
75. n listed in Additional Resources on page 10 for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 61 Chapter5 Field Device Integration Recommendations PROFIBUS PA The PROFIBUS PA network connects automation systems and process control Recommendations systems with field devices such as flow pressure and temperature transmitters Follow these guidelines for PROFIBUS PA networks e PROFIBUS PA isa master slave network e The number of devices on a PA segment depends on the following factors Area and classification Power supply voltage Amount of current each device consumes System update time Resistance of the segment cable e The voltage specification for the PA segment is 9 32V DC We recommend that you use a 24V DC PA power supply and be sure to keep the voltage above 13V DC at the farthest end of the segment e We recommend that you keep the PA segment below 24 devices for maximum performance e The cycle time for the PA network is determined by the bandwidth that each device fills This data is provided in the device s GSD files e Terminators reduce noise on segments caused by signal reflections at the end of an open cable One terminator on each end of the PA trunk is needed for proper operation PROFIBUS PA Communication Options PlantPAx systems communicate with PROFIBUS PA devices through EtherNet IP and ControlNet linking devices Table 23 PROFIBUS PA Interface
76. omation also provides tools to collect log files for submission to technical support The Rockwell Software Data Client program can browse the FactoryTalk directory to see all tags in the directory It can also get live data from any tag The Rockwell Software Data Client program does not automatically load the application Before you use it you must make sure the application is open by either opening the application from any computer with RSView Studio or by running an RSView SE Client For more information see these references depending on your operating system e Knowledgebase Answer ID 31073 Log Reader Tool XP Windows 2003 e Knowledgebase Answer ID 453900 Windows 7 Server 2008 Rockwell Automation Publication PROCES RM001F EN P October 2011 71 Chapter7 Maintenance Recommendations Services and Support System Support offers technical assistance that is tailored for process automation SM systems These services are available through TechConnect contracts Some of the features include the following e Highly experienced team of engineers with training and systems experience e Process support at a systems level provided by process engineers e Unlimited online support requests e Use of online remote diagnostic tools e Access to otherwise restricted TechConnect Knowledgebase content e Technical Reference Library DVD e 24 hour seven days per week 365 days per year of phone support coverage upgrade
77. omation com support ControlFlash Use the ControlFLASH Utility through RSLogix 5000 software to update firmware as documented in the ControlFLASH Firmware Upgrade Kit User Manual publication 1756 UM 105 Rockwell Automation Publication PROCES RM001F EN P October 2011 Maintenance Recommendations Chapter 7 Considerations when Upgrading Software and Firmware When installing a new PlantPAx system we recommend that you use the specifications in the PlantPAx Selection Guide publication PROCES SG001 When updating software or firmware versions you should verify the impact on performance and memory utilization before implementing the upgrade on the production system For FactoryTalk View or ControlLogix platforms you should carefully review the release notes and verify the impact of the upgrade on performance and memory utilization You should also verify the compatibility of the upgraded version with the other software and operating systems in use on your PlantPAx system Compatibility information can be found on Knowledgebase Answer ID 42682 Another tool http www rockwellautomation com compatibility scenarios lets you compare features and compatibilities of different products and firmware revisions You can contact Rockwell Automation Technical Support for assistance Monitoring Your System Certain system attributes can be monitored to determine the health of the PlantPAx system The table below provide
78. ommended max 750 750 1500 2250 Total tags max 31 250 31 250 62 500 125 000 Recommended control strategies max 125 125 250 450 Total control strategies 250 ms max 60 120 120 120 Total control strategies 500 ms max 120 125 220 220 Tags sec delivered to data server max 6 10 000 20 000 20 000 20 000 native instructions 1 These values are maximum limits You may not be able to achieve all of these in a single controller 2 Fora PlantPAx system we recommend that you use only the controller platforms characterized in this table If 1756 L64 or 1756 L65 controllers are used be aware that the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756 L63 controller typically 10 15 3 Representative control strategy PID loop includes 1 analog input 1 analog output 1 PIDE instruction 8 logic math instructions and up to 8 configured alarms with PlantPAx process objects and 4 Assumes RSLinx Enterprise software version 5 30 00 at 10 K sec per instance 5 We recommend that you configure alarming by using FactoryTalk Alarm and Events server based alarms See Alarm Implementation Recommendations on page 41 Rockwell Automation Publication PROCES RM001F EN P October 2011 23 Chapter 2 24 System Element Recommendations Determining 1 0 Count The I O count for controller sizing is often determined directly from the application P amp ID o
79. ontroller 21 redundant controller 23 skid based controller 22 skid based controller hardware 22 controller sizing 22 software antivirus 68 EWS 20 IIS 47 PlantPAx 18 updates 67 strategies control sizing 25 support services 72 switches Ethernet 52 synchronization commands 49 server and workstation time 48 system application recommendations 31 attribute definition 75 compatibility 67 core documentation 10 element definition 75 elements 15 FactoryTalk Batch 64 ferret tool 68 infrastructure definition 75 overhead time slice 32 procurement 16 server definition 75 support 72 tested 13 T tags controller 33 naming convention 34 task continuous 32 monitor 36 periodic 32 properties 32 recommendations 31 technical support 72 tested system 13 time workstation and server synchronization 48 tool 68 ControlFLASH utility 68 IAB 16 procurement 16 PSE 16 system ferret 68 update software 68 U UDT controller tags 33 definition 75 tag recommendations 34 update firmware 68 patches 68 software 67 tools 68 upgrade considerations 69 user defined tag definition 75 Rockwell Automation Publication PROCES RM001F EN P October 2011 utilization CPU 36 V virtualization 50 W workgroup recommendations 45 workstation definition 75 Rockwell Automation Publication PROCES RM001F EN P October 2011 Index 81 Index Notes 82 Rockwell Automation Publication PROCES RM001F
80. 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 only when the message needs 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 When messaging between controllers use DINTs where possible Message instructions consume a connection when it is a CIP data table read write or generic if selected Controller Tag Optimization When configuring displays we recommend that you use direct tag referencing to access data from the controller directly without creating an HMI tag This requires less configuration steps and is easie
81. or 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 Publications detail the EtherNet IP network that offers a full suite of control configuration and data collection services Batch PhaseManager User Manual publication LOGIX UM001 Explains how to define a state model for your equipment and develop equipment phases FactoryTalk Batch Installation Guide publication BATCH INO11 Provides information and procedures for installing FactoryTalk Batch software FactoryTalk Batch User s Guide publication BATCH UMO11 Provides a complement of FactoryTalk recipe management component guidelines and software installation procedures 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 Rockwell Automation Publication PROCES RM001F EN P October 2011 11 Preface Notes 12 Rockwell Automation Publication PROCES RM001F EN P October 2011 Chapter 1 System Architecture Recommendations The PlantPAx Process Automation System is a defined combination of standard Rockwell Automation Integrated Architecture IA products
82. orm definition 74 FactoryTalk Batch application guidelines 65 CSA attributes 63 system elements 64 FactoryTalk View SE OWS 20 field device documentation 10 firmware updates 68 footprint control strategy 26 FTAE device and server based 41 G global object definition 74 glossary 73 grouped elements 15 guidelines FactoryTalk Batch 65 PhaseManager 65 hardware redundant controller 23 simplex controller 21 skid based 22 historian definition 74 historical data definition 74 Rockwell Automation Publication PROCES RM001F EN P October 2011 HMI classic alarming 41 server FactoryTalk 18 1 0 considerations 27 determining count 24 process controller considerations 27 runtime 28 IAB tool 16 IIS graphics and components 47 implement alarms 41 independent architecture 14 infrastructure definition 45 documentation 10 recommendation 45 integrated architecture builder tool 16 definition 74 L_CPU Add On Instruction 37 LBSM controller based 63 load control strategy 27 controller 36 data log 39 example 27 localhost PASS server 19 M maintenance recommendations 67 memory controller properties 32 messages cache 33 monitor tasks 36 network recommendations 51 time protocol 48 Index 0 objects process library 40 operating system optimization 49 recommendations 45 operator workshop definition 75 optimize controller tags 33 operating system 49 options ala
83. part of a particular multicast group Select the switch depending on the network functionality Then Recommended Media Layer 3 switches Fiber Stratix 8300 e Cisco Catalyst 37606 or equivalent Cisco Catalyst 3750 or equivalent e Connecting control hardware sensors and workstations Isolated networks Layer 2 switches Stratix 8000 Stratix 6000 Cisco Catalyst 29xx or equivalent 1585 series copper media High availability at switch level 1 52 For uplink cables between Layer 2 3 fiber is recommended for 1 Layer 3 switch Fiber Stackwise 37606 or equivalent GB connectivity For more information see these resources Ethernet switches Ethernet Design Considerations Reference Manual publication ENET RMO02 Ethernet switch configuration Converged Plantwide Ethernet CPwE Design and Implementation Guide publication ENET TDO001 Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 17 EtherNet IP Interface Category ControlLogix controller interface Infrastructure Recommendations Chapter 4 Controller and 1 0 Ethernet Adapters The EtherNet IP network also supports controller downlinks and connections to remote I O and field device interfaces Product Description 1756 EN2T 1756 EN2TR 1756 EN2F ControlLogix EtherNet IP scanner 1756 ENBT 1756 EWEB 1757 FFLD2 EtherNet IP to FOUNDATION Fieldbus linking device Support
84. r 02 100 000 0524 10 413e 41 us 500 000ue Shon Programa gt gt Max Desired Scan Rate s 0 Tme Sice 202 Pese Max Scar Hest Oyeren Court T Log Firmar 17 02 57 Processes 07 CPU Utliz tion 38 Rockwell Automation Publication PROCES RM001F EN P October 2011 System Application Recommendations Chapter 3 Processor Utilization L_CPU The Logix Controller CPU Utilization L_CPU Add On Instruction monitors the Logix controller executing it and is used in place or addition to the Task Monitor to provide more system specific controller loading information Information 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 The diagram in Figure 3 shows a properly loaded controller for the following e Allocation code execution I O processing is less than 70 CPU e Expected communication is less than 30 CPU Figure 3 CPU Utilization 27 07 Communication Time 9 785 Tags Second Nuk 22 14 100 ms Task User 37 69 A Application Code 250 ms Task 37 69 Execution Comms 27 07 System 13 10 500 ms Task 13 10 L 1 0 System Processing System Processing Time System Background Task Time See the Process Add On Instructions Processor Utilization L_CPU in the Knowledgebase Answ
85. r 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 on transmitters on an EtherNet IP network any signal from the device used by your control strategy is considered an I O point One 1 0 channel per each 1 0 point on an 1 0 module One 1 0 channel per each device ina networked motor control center NE Mae MAS For example an I O count for a system comprised with the following e Two 8 channel 4 20 mA input cards e One 8 channel 4 20 mA output cards e Two 16 channel 24V DC dry contact input cards e One MCC with six drives on EtherNet IP Each drive provides six signals to the control strategy speed reference actual speed start stop running and fault e Two Coriolis meters on PROFIBUS PA with each meter providing three signals for flow temperature and density The I O count example has the following calculation 4 20 mA AI 2x8 16 4 20 mA AO 1x8 8 24V DC DI 2x 16 32 MCC 6x6 36 6AI 6 AO 12 DI 12 DO Smart instruments 2x3 6 6AI Controller I O count 98 TIP When calculating 1 0 count for controller sizing it is good practice to add spare capacity to allow for project changes or future enhancements This could be accounted for by spare channels on existing systems or by
86. r to maintain Use DINT and REAL data types whenever possible Mathematical routines in the controller consume less memory when DINT and REAL data types are used A user defined data type UDT lets you organize data to match your machine or process Additional advantages of a UDT include the following e 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 e Each individual piece of data member gets a descriptive name This automatically creates an initial level of documentation for your logic e 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 Rockwell Automation Publication PROCES RM001F EN P October 2011 33 Chapter3 System Application Recommendations You can create a UDT when online or offline However you can only modify an existing UDT definition when offline General Recommendations e 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 e When defining a UDT group BOOL tags together whenever possible Inside the controller memory BOOL tags must align on 8 bit boundaries But if
87. re that includes controllers I O networks drives cabling and wiring motion control and other devices IAB also includes a Process System Estimator PSE to size your process control hardware By entering data of your system requirements an optimal architecture can be defined to feed into the IAB tool See http www rockwellautomation com en e tools configuration html Rockwell Automation Publication PROCES RM001F EN P October 2011 Chapter 2 System Element Recommendations PlantPAx system elements refer to the individual servers clients and controllers that comprise a PlantPAx system These building blocks are the foundation of your system architecture The following table describes what this chapter contains and where to find specific information Topic Page PlantPAx Software Components 18 Process Automation System Server PASS 18 Engineering Workstation EWS 20 Operator Workstation OWS 20 Process Controller 21 AppServ HMI 30 Plant Asset Process Management Information mm a AE Plant Ethernet Batch Engineering Operator Workstations Process Automation Management Workstation System Servers _ E TA T 7 Sia N E ie Process Control EtherNet IP ee Variable Speed Drives Process Controllers ET JON sl 1 0 Network d 8 a EtherNet IP Local Distributed and Intelligent 1 0
88. rms 41 process library 40 overview system elements 17 ows description 20 element 15 FactoryTalk View SE 20 P P_ALARM Add On Instruction 43 PASS definition 75 description 18 element 15 redundancy 20 system element 18 patches updates 68 performance critical system attribute 15 periodic tasks 32 PhaseManager guidelines 65 PlantPAx architecture 13 definition 9 infrastructure 45 selection guide 16 software 18 system definition 75 process controller sizing 21 library objects 40 library recommendations 43 system estimator 16 processor element 15 procurement tools 16 produced and consumed controller tags 33 properties 32 controller memory 32 tasks 32 PSE tool 16 Rockwell Automation Publication PROCES RM001F EN P October 2011 79 recommendations alarms 41 architecture 13 batch 63 controller 31 domain 46 FactoryTalk 38 FactoryTalk alarms 42 infrastructure 45 maintenance 67 network 51 operating system 45 process library 43 system application 31 system elements 17 tasks 31 UDT tags 34 workgroup 45 47 redundancy AppServ HMI 30 controller hardware 23 controller sizing 23 PASS configurations 18 PASS server 20 reference manual scope 9 reporting errors 50 RSLinx software definition 75 runtime 1 0 considerations 28 S scope reference manual 9 server definition 75 server based alarms 42 simplex controller hardware 21 controller sizing 21 sizing control strategies 25 process c
89. rocurement Tools ninas ed 16 Chapter 2 PlantPAx Software Components cia cido 18 Process Automation System Server PASS 2 0s ee eeeee eee eee 18 Set Up the Factory Talle Directory erario 19 PASS Server Redundancy 4 014 422 de Cera ae Uco 20 Engineering Workstation EWS ii ips 20 Operator Workstation OWS siria a eeu tonamen 20 Process Controller 21 Simplex Controller asias rc 21 Skid based Controller A A E 22 Redundant Control erst sso eae ie sed dorcel a tanane 23 Determining I O Counts ds wey 2 lee cee eat h se Oo ees laid 24 Sizing Control Strategies isa 25 Process Controller I O Considerations ooooooocmmmmom 27 PROSE Poer riika en AS 30 AppServ HMI Redundancy ira ears 30 Chapter 3 Controller Recommendations 00cccceccecuceccecucvevees 31 Process Controller Configuration idea 31 Using Periodic Tasks idad ro 32 Controller Project Considerations icini new soue vino naw ee 33 Controller Tag Opirata ee Atte 33 Using Add On Instructions vcd anes 35 Process Controller Utilization oooooomommom o lt o 36 Factory Talk View Recommendations 4 Licores orici dls dad 38 Data Log Recommendations rc neos 39 PlantP Ax Library of Process Objects coria ais 40 Alarm Implementation Recommendations oooooooconccccrcccooo 41 HMI Classic Alarm Recommendations oooooooococncrm 41 General Factory Talk Alarm Recommendations 42 Factory Talk Server based Alarm Recommendat
90. rs 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 See AppServ HMI on page 30 for more information FactoryTalk View Alarms and Events server The Alarms and Events server is an optional component on the PASS that makes alarm information from controllers and servers available to all subscribing OWS stations Alarms and Events servers are configured within your FactoryTalk View SE application There are two types of Alarms and Events servers device based alarm and event servers that is configured as an option to the data server and server based alarm and event servers configured as a separate component The Alarms and Events server mentioned in PlantPAx documentation refers to the Alarms and Events server that is used for server based alarms You can have up to two Alarms and Events servers on the PlantPAx system These may exist on the PASS or an AppServ HMI See Alarm Implementation Recommendations on page 41 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 these components are included on the primary PASS only See PASS Server Redundancy on page 20 for more information
91. rus software Rockwell Automation Software Firmware Updates We recommend that you periodically review and update the available software patches and firmware updates for the Rockwell Automation components on your PlantPAx system Before implementing Rockwell Automation updates you should verify them on a non production system or when the facility is non active to ensure that there are no unexpected results or side effects For Rockwell Automation software that is FactoryTalk View Factory Talk Batch FactoryTalk Historian SE and FactoryTalk AssetCentre Rockwell Automation provides the Patch Validator tool This tool verifies the current file version installed the expected file version based on the version of Patch Validator user and completes installation of patch roll up The Patch Validator tool is available for download via the Knowledgebase Answer ID 30393 For Rockwell Automation firmware Rockwell Automation provides a System Ferret tool that can be installed on the EWS to collect device serial numbers and revisions of all devices through RSLinx Classic software System Ferret is available through ab com as an Integrated Architecture Productivity Tool see http www ab com go iatools The devices and firmware listed can be compared against the latest firmware compatible with your Logix firmware version by reviewing the firmware compatibility You also can download the latest firmware release at http www rockwellaut
92. s monitoring recommendations Table 25 PlantPAx System Monitoring Recommendations System Attribute How To Monitor FactoryTalk View HMI Server Status In FactoryTalk View Studio in the Explorer window right click the HMI servers icon and then click Server Status You also can create a server monitoring screen as described in Knowledgebase Answer ID 44624 Description Make sure the Primary server status is active Changes made using FactoryTalk View Studio will always occur on the active server If the Primary HMI server computer is or was down then the Secondary could be the active server You do not want your HMI server project edits to occur on the Secondary HMI server computer because the replication operation works only in one direction from the Primary HMI server to the Secondary HMI server If you accidently do your editing on the Secondary HMI project when you eventually replicate the Primary HMI server project it will overwrite the Secondary HMI server project and all the editing that was done will be overwrite and lost Windows Event Logs Event Viewer Windows Administration Tools Browse the following logs looking for errors or warnings Application Event Log Security Event Log System Event Log Event Viewer Windows Administration Tools or FactoryTalk Tools Diagnostic Viewer FactoryTalk Diagnostics Browse looking for errors or warnings Default location is c Windows system32 Logf
93. s two or four H1 1757 FFLD4 FOUNDATION Fieldbus networks 1788HP EN2PA R HIPROM Technologies EtherNet IP to PROFIBUS PA linking device Supports redundant PA media and DLR capable Ethernet 1 Can be ordered directly from HIPROM Technologies not a Rockwell Automation product catalog number Follow these EtherNet IP communication module guidelines e Disable keying on EtherNet IP communication modules e Cannot bridge EtherNet IP I O modules across networks I O modules have to be in either a local or remote chassis not bridged through backplanes e Ethernet communication modules must be in a separate rack if you are using a rack optimized communication format Use the Ethernet modules diagnostic page to monitor these fields Speed and duplex are at fixed 100 Full Current CIP MSG connections are within limits Current CIP I O connections are within limits Make sure there are no connection timeouts Current TCP Connections are within limits Packets second counters should be within each device s capacity Make sure there are no missed I O packets Make sure Ethernet module use is 80 Media counters should be near 0 and not incrementing In Error and Out Error counters should be near 0 and not incrementing Rejected packet counters should be near 0 and not incrementing Rockwell Automation Publication PROCES RM001F EN P October 2011 53 Chapter4 Infrastructure Recommendations Notes 54 Rockwell Autom
94. strategies max 60 125 250 125 250 450 450 Total control strategies 250 ms max 60 125 125 125 250 250 250 Total control strategies 500 ms max 60 125 250 125 250 450 450 Tags sec delivered to data server max 5 10 000 10 000 10 000 20 000 20 000 20 000 20 000 1 These values are maximum limits You may not be able to achieve all of these in a single controller 2 Fora PlantPAx system we recommend that you use only the controller platforms characterized in this table If 1756 L64 or 1756 L65 controllers are used be aware that the additional management of the extended memory space may impact the CPU utilization of the controller when compared to a 1756 L63 controller typically 10 15 native instructions 4 Assumes RSLinx Enterprise software version 5 30 00 at 10 K sec per instance 5 We recommend that you configure alarming by using FactoryTalk Alarm and Events server based alarms See Alarm Implementation Recommendations on page 41 Rockwell Automation Publication PROCES RM001F EN P October 2011 3 Representative control strategy PID loop includes 1 analog input 1 analog output 1 PIDE instruction 8 logic math instructions and up to 8 configured alarms with PlantPAx process objects and 21 Chapter2 System Element Recommendations Table 5 Skid based Controller Hardware Hardware Process controller Table 6 Skid based Controller Sizing Skid based Controller PlantPAx supports small footprint
95. t use CPU cycles and even a portion of RAM just to manage the paging process Furthermore hard disk access times are measured in milliseconds as opposed to RAM access times that are measured in nanoseconds Therefore the paging process can waste a lot of server resources to move pages of data back and forth between memory and virtual memory Thrashing is a term for nearly constant paging If the hard disk is running constantly with no visible results and a very sluggish response time the system may be thrashing Paging Utilization percentage can be used to indicate this condition to the user The appropriate Paging Utilization percentage can depend on the virtual memory setup on the server It is best to baseline the paging file performance and set alert limits when performance significantly deviates from this baseline For example generate alert if Paging Utilization gt 90 Additional Monitoring Resources The Counter Monitor tool is installed with the FactoryTalk Services Platform FTSP on the PASS and AppServ HML It is located on the drive where FTSP is installed under Program Files Common Files Rockwell countermonitor exe Counter Monitor provides the ability to monitor the runtime values of counters and strings that are made available by network clients for diagnostic purposes You also can use the Counter Monitor tool to take a snapshot of the current status and submit it to Rockwell Automation Technical Support Rockwell Aut
96. ta Set interval to 1 second or greater Defragment data drive usually drive D daily with a third party package for better retrieval performance z x Models x Models yyy Points logged yyy Points logged every second every second AppServ HMI Number of Trends Number of Pens lt Number of Models Accessed Historical Data requested Remote Racks Rockwell Automation Publication PROCES RM001F EN P October 2011 OWS 39 Chapter3 System Application Recommendations PlantPAx Libra ry of Process The PlantPAx Library of Process Objects is a predefined library of controller Obj ects 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 This library is available from the Knowledgebase Answer ID 62682 at http rockwellautomation custhelp com complete with instruction documentation Step 3 Access a faceplate from the global object at runtime for control and maintenance Step 2 Drop the global Step 1 D d CP aE an object on display and configure AOI assign to AOI instance A g araa vela SL omme E mE Pet E r u 94 43 GPM DE l I J 45827 The PlantPAx Library of Process Objects is supported through Rockwell Automation Technical Support as longas the Add On Instructions have not been
97. tamped within 1 second Alarm burst time All alarms in a burst of 1000 alarms are timestamped within 3 seconds Recovery Asystem element returns to full operation within 5 minutes of the restoration after a failure or loss Data logging The system supports local HMI data logging of 200 points once a second 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 Aserver 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 RM001F EN P October 2011 15 Chapter1 System Architecture Recommendations System Procurement Tools 16 The following chapters of this manual contain recommendations and considerations for implementing your system If you have not selected or procured your PlantPAx system architecture and components see page 18 see the PlantPAx Selection Guide for more information including use of the Integrated Architecture Builder IAB tool Rockwell Automation offers the IAB tool to help create a bill of material for an automation system This graphical software tool helps you select hardwa
98. tate hold command The time from the hold command to the first scan of the holding routine is no more than 1 second Running state stop command The time from the stop command to the first scan of the stopping routine is no more than 1 second Running state abort command The time from the abort command to the first scan of the aborting routine is no more than 1 second Rockwell Automation Publication PROCES RM001F EN P October 2011 63 Chapter6 Batch Management and Control Recommendations Table 24 FactoryTalk Batch CSA Batch Critical System Attribute Held state restart command Performance The time from the restart command to the first scan of the restarting routine is no more than 1 second Held state stop command The time from the stop command to the first scan of the stopping routine is no more than 1 second Held state abort command The time from the abort command to the first scan ofthe aborting routine is no more than 1 second Phase fail transition The time from the phase failure initiation to the held state is no more than 1 second Phase transition time Install FactoryTalk Batch Client Components 64 The time from for one phase to complete and another to start is no more than 1 second When using Factory Talk Batch on a PlantPAx system the Factory Talk Batch components should be the first items installed on the PASS AppServ HMI OWS and EWS This is because F
99. ted field device networks or protocols e Enterprise wide solution by using FactoryTalk AssetCentre Rockwell Automation Publication PROCES RM001F EN P October 2011 55 Chapter5 Field Device Integration Recommendations EtherNet IP 1 0 Recommendations Table 18 EtherNet IP Interface Category ControlLogix controller interface 56 FactoryTalk AssetCentre for Enterprise Solution FactoryTalk AssetCentre software is a server based centralized tool that lets you 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 allows any device to be accessed from FactoryTalk AssetCentre software regardless of the communication method The FDT interface also allows FactoryTalk AssetCentre software to integrate many different kinds of devices including handheld diagnostic tools For more information see the following publications e FactoryTalk AssetCentre Product Profile publication FIALK PP001 e FDT website at http www fdtgroup org 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 called the Common Industrial Protocol CIP A growing number of field devic
100. therNet IP network Table 11 Online Addition of Module and Connection Types 1756 Module Type and In Local Chassis In Remote Chassis Via a ControlNet Network In Remote Chassis Via an Communication Method EtherNet IP Network Offline Runtime Offline Runtime Offline Runtime Scheduled Unscheduled Scheduled Unscheduled Analog direct Yes Yes Yes Yes No Yes Yes Yes Generic third party direct Yes Yes Yes Yes No Yes Yes Yes 1756 DNB Yes No Yes No No No Yes Yes 1756 DHRIO Yes No Yes No No No Yes Yes 1756 CNx no connection Yes Yes Yes Yes No Yes N A N A 1756 CNx rack optimized N A N A Yes N A N A N A N A N A 1757 FFLDx linking device N A N A N A N A N A N A Yes Yes 1757 FFLDC linking device N A N A Yes Yes No Yes N A N A 1788HP EN2PA R N A N A N A N A N A N A Yes Yes 1788HP CN2PA R N A N A Yes Yes No Yes N A N A 1756 ENx no connection Yes Yes N A N A N A N A Yes Yes 1756 ENx rack optimized N A N A N A N A N A N A Yes Yes Generic EtherNet IP N A N A N A N A N A N A Yes Yes third party direct 28 Rockwell Automation Publication PROCES RM001F EN P October 2011 Table 12 Adding 1 0 Modules at Runtime Design Issue 1 0 modules System Element Recommendations Chapter 2 When you design your network review these considerations if you are going to add I O modules at runtime Consideration Currently only 1756 1 0 modules can be added at runtime Le
101. they are placed adjacent to each other they can share the same byte and use less memory and communication bandwidth e 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 e Define a tag naming convention that minimizes the length of the tag names Long tag names can decrease the bandwidth available for communicating data See the Logix5000 Controllers I O and Tag Data Programming Manual publication 1756 PM004 for more information 34 Rockwell Automation Publication PROCES RM001F EN P October 2011 System Application Recommendations Chapter 3 Using Add On Instructions Add On Instructions are reusable codes that contain encapsulated logic that can streamline implementing your system This lets you create your own instruction set for programming logic as a supplement to the instruction set provided natively in the ControlLogix firmware An Add On Instruction is defined once in each controller project and can be instantiated multiple times in your application code as needed In RSLogix5000 you can view the routines within an Add On Instruction instance online animated with just that instance s value as if it were an individually defined routine Add On Instructions also can be source protected which means users without the source key cannot e
102. tion controller 33 definition 73 description 35 L_CPU 37 P_ALARM 43 advanced controller properties 32 alarms and events server FactoryTalk 18 device based 42 FactoryTalk recommendations 42 HMI classic 41 implementation 41 server based 42 antivirus software 68 application FactoryTalk Batch guidelines 65 server definition 73 element 15 system recommendations 31 AppServ HMI considerations 30 redundancy 30 architecture builder tool 16 centralized 14 classes 14 critical system attribute 15 definition 73 distributed 14 independent 14 PlantPAx 13 recommmendations 13 attributes CSA 15 FactoryTalk Batch 63 redundant controller 23 batch critical system attribute 63 documentation 11 equipment phases 65 management 63 recommendations 63 server FactoryTalk 18 BOOL tags 34 Index C cable types 51 cache messages 33 centralized architecture 14 characterization definition 73 system tested 13 classic HMI alarming 41 classification architecture 14 client definition 73 compatibility system 67 components PASS 18 PlantPAx software 18 configuration controller 31 FactoryTalk directory 19 considerations AppServ HMI 30 controller project 33 EtherNet IP interface 56 process controller 1 0 27 upgrade 69 continuous task 32 control batch management 63 strategies 25 strategy analog indicator 26 definition 73 ControlFLASH 68 controller 27 Add On Instructions 33 advanced 32 configuration 31 count 15 e
103. ts server and its associated data server Whenever possible use Digital Alarms to perform the alarm detection in the controller to generate a Boolean indication of the alarm condition Use the import and export features in FactoryTalk View SE when you need to configure a large number of alarms FactoryTalk Device based Alarm Recommendations 42 An application is limited to two RSLinx Enterprise servers with FactoryTalk Alarms and Events FTAE enabled For large applications consider separating the data server used for device based alarms from the data server used for display data You can do this by creating a separate AppServ HMI that contains only the RSLinx Enterprise server with FTAE enabled We recommend that you use ALMA and ALMD instructions for only the most critical or time critical alarms There are no hard coded limitations but when ALMA and ALMD are used we recommend limiting the number of instructions to 250 per redundant controller 1000 per L x simplex controller or 2000 per L7x simplex controller Be aware that controller scan time and memory usage is variable with the use of FTAE 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 RSLinx Enterprise 100 KB Rockwell Automation Publication PROCES RM001F EN P October 2011 Application Development Reso
104. ublication PROCES RM001F EN P October 2011 31 Chapter3 System Application Recommendations Table 13 Controller and Task Recommendations Attribute Task Properties Recommendation Tolimitthe amount of task switching we recommend that priority be assigned based on scan rate with faster tasks getting higher priority configured by entering a lower number Do not use the same priority for multiple tasks Set the watchdog to at least three times the task period This specifies how long a task can run before triggering a major fault e Inhibit or delete unused tasks e To allow for communication load it s recommended that the total execution time of all tasks is less than half of your fastest task rate For example if your fastest periodic task runs at 500 ms the total execution time of all tasks should be lt 250 ms e CPU utilization varies based on communication status When you are online you can monitor the execution of your tasks from the Monitor tab of the Task Properties window e An overlap is a condition where a task periodic or event is triggered while the task is still executing the previous scan You should also check that you are not experiencing task overlap by verifying the task overlap count is 0 Controller Properties Advanced The system overhead time slice does not need to be set when a continuous task is not configured Controller Properties Memory It s recommended to keep 50 of avail
105. unk is needed for proper operation Use power supplies and power conditioners with built in short circuit protection Redundant power supplies are available One and only one Link Active Scheduler LAS can be present on each H 1 segment at one time You might have one frame where a device is reporting an error then a gap of silence a device transmitting data then another gap of silence and so forth The LAS directs this traffic Another device can be a backup LAS FOUNDATION Fieldbus Communication Options PlantPAx systems communicate with FOUNDATION Fieldbus devices through EtherNet IP and ControlNet linking devices Table 22 FOUNDATION Fieldbus Interface Category EtherNet IP interface Product 1757 FFLD2 1757 FFLD4 Description Bridge from an Ethernet network to either two or four H1 networks ControlNet interface 1757 FFLDC2 1757 FFLDC4 Bridge from a ControlNet network to either two or four H1 networks compatible with ControlLogix redundancy and redundant ControlNet media FOUNDATION Fieldbus network components Power conditioning Pepperl Fuchs FOUNDATION Fieldbus components such as valve couplers surge Terminators protectors terminators distributors and power products See the Encompass website for Pepperl Fuchs product offerings Segment protection Configuration software 9308 series RSFieldbus software Configure FOUNDATION Fieldbus devices See the documentatio
106. urces Topics and Tools PlantPAx Library Example execution times System Application Recommendations Chapter 3 ALMD in a 1756 L63 controller with no alarm state changes 8 ys ALMD in a 1756 L63 controller with alarm state changes 35 ys In redundant controller configurations crossloading of redundancy can add up to 70 us per ALMD instruction See the Logix5000 Controllers Execution Time and Memory Use Reference Manual publication 1756 RM087 for more information Using the PlantPAx Library of Process Objects for Alarms The PlantPAx Library uses a dedicated Add On Instruction titled P_ALARM for each configurable alarm in the library elements Documentation is provided with the Process Library to describe how to connect the Add On Instruction instances with the HMI server for Classic Alarming or with Tag Alarm and Event Server for FactoryTalk Alarming We do not recommend the use of Classic Alarming and FactoryTalk Alarm and Events together in a single application However we do recommend the use of HMI Classic Alarming for your FactoryTalk View ME applications and FactoryTalk Alarm and Events Alarming for your FactoryTalk View SE application which can both talk to the same controller The following resources are available for use to assist with developing your application Description Diagnostic objects and enhanced process instructions to accelerate system engineering See page 40 for details Where To Find In
107. ure these policy settings they will override any adjustments to error reporting that are made via the Control Panel procedures Virtualization Virtualization breaks the dependency between operating system and physical hardware allowing multiple virtual machines to run different operating systems and applications from varying locations on the same server You also have the ability to upgrade hardware without replacing the operating system on individual workstations Rockwell Automation supports virtualization on VM Ware s ESXi architecture for the PASS EWS OWS and application servers Contact a Rockwell Automation Support Representative for more information Rockwell Automation Publication PROCES RM001F EN P October 2011 Infrastructure Recommendations Chapter 4 Network Recommendations The Ethernet network provides the communication backbone for the supervisory network for the workstations servers and the controllers Type Fiber optic Configure all communication interfaces to operate at 100 MB full duplex do not use autonegotiate for 10 100 network adapters 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 and this may interfere with network throughput If multiple DCOM protocols are installed and set up on a workstation to make sure that DCOM communications function correctly
108. ween samples in seconds The default is 2 s dataonly To display only the data without graphics The w32tm resync command manually forces a computer to resynchronize its clock to the domain controller as soon as possible and resets error statistics Operating System Optimization The following recommendations will enhance the performance of your operating system e Turn off Windows automatic updates to 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 e Disable operating system themes which allow for 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 e 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 e Data Execution Prevention DEP should be turned on for workstations running FactoryTalk View SE components This security feature protects against viruses and other security threats by preventing unauthorized programs from running executable program code e Remove Enhanced Security Configuration ESC from workstations running FactoryTalk View SE software The Windows 2008 security settings protect servers
109. y lated die M8 a O e de DO elos Lo 73 aa aa on di nda 77 Rockwell Automation Publication PROCES RM001F EN P October 2011 1 Table of Contents Notes 8 Rockwell Automation Publication PROCES RM001F EN P October 2011 Preface The PlantPAx Process Automation System is a defined set of standard Rockwell Automation Integrated Architecture products that are configured in a prescribed way to provide optimal performance as a process automation system When Process Automation System combining PlantPAx core system components tools and utilities with other Rockwell Automation and partners products the result is unmatched automation system flexibility scalability and expandability when solving continuous batch as well as high speed discrete applications Whereas the PlantPAx Selection Guide is used to assist with equipment procurement after defining system requirements this Reference Manual elaborates on what you need to know to set up a PlantPAx system as shown in Figure 1 Figure 1 Reference Manual Scope System Setup amp Configuration System Architecture System Element System Application Infrastructure Field Device Batch Maintenance 32204 MC Reference Manual The Reference Manual content is organized in logical order from configuring system elements to developing applications You do not need to read the sections in sequential chapter order If you already have configured workst

Download Pdf Manuals

Related Search

Related Contents

Libretto Radiatore gas RGL 32 41 48  Pour les Laboratoires Pharmaceutiques  Manual de instrucciones Manual de instruções    Cahier des charges test de compétence_CN30102014  BC-12 Voorhoofd thermometer  Operation Manual 12/29/2009  Samsung GT-P7300/M16 Benutzerhandbuch  Para Masajes de Presión Profunda  Fujitsu MAM3184MC/MP User's Manual  

Copyright © All rights reserved. Failed to retrieve file