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                                                                                                                                                                                                   Engineering Workstation Capacity                               Operator Workstation Capacity
                             Domain Controller Configuration
                                                                                                                                                                                                   • Can configure all system controllers                         • 20 Operator Workstations
                             • Win 2003 Server No SP                                                                                       System Server Capacity
                             • Active Directory                                        System Capacity                                                                                             • Can configure and manage operator
                                                                                                                                           • Process Area C
                             • Kerberos Authentication protocol                        • 1 Factory Talk RSView SE                                                                                    workstations displays
                                                                                                                                           • HMI Server
                             • DNS Server                                                Distributed Application                           • 1 Data Server
                             • WINS Server                                             • 4 Process Areas                                   • Display Update Setting 0.5 or 1.0                    Engineering Workstation Configuration
                             • No DHCP, Static IP addresses                            • 20 Clients                                                                                               • Win 2003 Server                                                                 Operator Workstation Configuration
                                                                                                                                           • 40k tags on Scan for Displays
                             • No Routing                                              • 1500 Loops                                                                                               • RSView Studio CPR 7                                                             • Win XP SP2, Firewall OFF
                                                                                                                                           • 20k Alarms tags per area each
                             • System wide time synchronization with                                                                                                                              • RSView Run Time Client                                                          • Windows Classic Theme
                                                                                                                                             with ACK and handshaking feedback
                               Reliable Time source Network Time Protocol                                                                                                                         • RSLinx Enterprise                                                               • RSView SW CPR 7
                               (NTP) for clock synchronization for all                                                                                                                            • RSLogix 5000                                                                    • RSView HMI Client
                               computers on Domain                                                                                         System Server Configuration                            • RSNetworks (for Enet and Cnet)
                                                                                Domain Controller                                                                                                 • RSLinx Classic
                                                                                                                                           • Win 2003 Server No SP
                                                                                Computer                                                                                                          • NI Configurator ver 3.2 (optional)
                                                                                                                                           • Factory Talk Directory
                                                                                Configuration                                                                                                     Optional
                                                                                                                                           • RSView Studio CPR 7
      System Data Logger                                                        • Pentium                                                                                                                                                                   Operator Workstation
                                                                                                                                           • RSLinx Enterprise                                    • RSTunes
      Configuration                                                             • 2.0 GHz CPU                                                                                                                                                               Computer Configuration
                                                                                                                                           • RSLinx Classic                                       • RSLoop Optimizer
      • Win 2003 Server No SP                                                   • 1 GB Memory                                                                                                                                                               Pentium
                                                                                                                                           • Controller time synchronization via
      • Microsoft SQL2000 SP4
      • Process Alarm History
                                                                                                                                             RSLogix Clock Tool                                                                 Engineering
                                                                                                                                                                                                                                                            • 2.0 GHz CPU
                                                                                                                                                                                                                                                            • 1 GB Memory
      • System Event History                                                                  Server                                                                                                                            Workstation
      • System Error/Diagnostic         System          Domain
        History                         Data            Controller
                                                                                              Configuration                                                                                                                                                       NIC Configuration                                     Operator
                                        Logger                                                • Dual Pentium                               System                                                                                                                                                                      Workstations
                                                                                                                                           Server                                                                                                                 • 100 Mbs
                                                                                              • 3.0 GHz CPU                                              Layer 2 Switch                                                                                           • Full Duplex
B                                      Layer 2                                                • 2 GB Memory
                                                                                                                                                                                                                                 Server Computer
                                                                                                                                                                                                                                 Configuration                    • Power Management OFF
                                       Switch                                                                                                                                                                                    • Dual Pentium                   • File & Printer sharing max
                                                                                                                                                                                                                                 • 3.0 GHz CPU                      data throughput for
                                                                                                                                                                                                                                                                                                    Layer 2 Switch
                                                                                                                                                                                                                                 • 2 GB Memory                      network applications

                                                                                                                   ENBT or EWEB Configuration
                                                                                                                   • Full Duplex
                                                          Remote I/O Capacity                                                                                                Layer 2 Switch
                                                                                                                   • 100 Mbs
                                                          • 64 modules per controller                              • Auto Negotiate OFF
                                                          • 8 Remote Racks per controller
                                                          • 1024 I/O points

                                                           Remote I/O Configuration                                                                                                                                                         ControlLogix Configuration
                                                           • 25 ms unscheduled RPI                                                ...                                                      ...                                              • 1756-L63 Processor
                                                                                                                                                                                                                                            • Version 15 Firmware
                                                                                                 CLX 1                                  CLX 6                     CLX 7                          CLX 12                                     • S88 based code implementation
    CN2FF Configuration
                                                                                                                                                                                                                                            • 250 ms Periodic Scan rate                    ControlLogix Capacity
    • Hardware you need: Power Supply, Power
                                                                                                                                                                                                                                            • 200 ms Program Scan                          • 1024 I/O points
    • Conditioner, Fieldbus cable, Devices,
      Connector blocks,                                                                                                                                              Area Capacity                                                                                                         • 125 Control Strategies (Loops)
      Terminal blocks, Terminators                                                                                                                                   • Up 12 Controllers
                                                                                      IO Racks
    • Configuration/Setup, Setup Basic Function                                                                                                                      • 12,288 I/O points
      Blocks, Design Power circuit, Design Network                                                                                                                   • 1500 Loops
      Topologies, Setup Link Master, Configure
      and Calibrate
    • Scheduled as an I/O rack
    • H1 network requires power supply, power           Foundation
                                                         Fieldbus                     Foundation
      conditioner, terminators and FF cable
A   • 1797-BCNR Redundant ControlNet Barrier                HI                         Fieldbus
                                                                                          HI                                                                                                                                                    System Performance:
                                                                                                                                                                                                                                                • Display Callup                                                                       A
                                                                                                                   Classic I/O HART                                                                                                                - Screen fully displayed and functional in 2 seconds
    CN2FF Capacity                                                                                                                                                                                                                              • Display Update
    • 24 of instruments per CN2FF                                                                                   Redundant ControlNet                                                                                                           - A change in any controller will be reflected on a HMI graphic in 1 second
    • 2 H1 segments per CN2FF                                                                                                                                                                                                                   • Steady State Alarms
    • 12 FF instruments per segment                                                                COMM   STATUS                                                                                                                                   - System will time stamp and log alarms at a sustained rate of 20/second
                                                                                                                                      DeviceNet Capacity                                                                                        • Alarm Burst
    • Redundant transmitters should be installed in
                                                                                                                                      • Up to 63 nodes                                                                                            - System will time stamp and log alarms within 3 seconds of a burst of 1000 alarms
      sparate H1 networks and separate FFD’s                                                                                                                                                               Motor Control
                                                                                                                                      • Trunkline can be up to 500 m                                                                            • Alarm Resolution
    • Each H1 should have a separate power supply                                                                                                                                                          Center (MCC)
                                                                                                                                        with out repeaters                                                                                         - Granularity of alarm time stamp in 1 second
      and conditioner                                                                                                                                                                                      Intellcenter
                                                                                                                                      • Each device can be up to 6m                                                                             • Keyboard Entry
    • CN2ff Limits
                                                                                                                                        from trunk                                                                                                 - A change from the keyboard is reflected in any controller with 1 second
    • 1788-CN2ff - 2 Links, 30 Connections
      (16in/16 out), 16 Devices

                                                                                                                                                                                                                                             Centralized System                (Single Server/Multi Client)
    Publication: Proces-AP006A-ENE November 2006                                                                                                                                                                                                         Integrated Architecture for Process Control
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    Centralized System Bill Of Materials                                                                                                                               About this Configuration – Centralized Process Automation System
Important: The Integrated Architecture for Process Control System is a defined, bounded system that when applied as specified will deliver known     The IA based Process Automation System presented in this diagram is assembled from standard “System Elements” to provide a common; hardware and control platform,
system performance and is intended to meet the system operational requirements expected by process control (DCS) users. The IA for process system    engineering & control environment, HMI, and information infrastructure.
characterization data provided is derived from standard Rockwell Automation products; applied and tested in the configuration specified and may be
different than the published performance, capacity, and configuration data for the individual components.                                            Common hardware platform - the IA based Process Automation System utilizes the ControlLogix L6x series of controllers and the 1756 IO family.
                                                                                                                                                          - Broad range of IO modules include analog, discrete and specialty IO types permitting effective use across a variety of applications.
  The centralized system expands the independent system scope by increasing the number of controllers the system can support                              - IO modules are software configurable; analog IO have 16 bit resolution, over/under-range detection and engineering unit scaling with support for either floating point
  and by adding separate workstations (personal computers) and servers for operations and engineering functions at the supervisory                        or integer, discrete IO support up to 32 points, and can include built in diagnostics such as broken wire detection.
  level. The centralized system easily supports the concept of a Main Control Room (MCR), yet enables you to mount operator                               -All ControlLogix platform modules support Removal & Insertion Under Power (RIUP) and adding IO on line
  workstations locally throughout the production facility. The centralized system includes the same software as the independent
  system. In addtion, a centralized system provides:                                                                                                 Multi-disciplined controller provides a highly effective way to implement the various control disciplines including for continuous, batch, discrete and motion applications.
                                                                                                                                                           - Multitasking Controller for segmenting the control strategies to allow executing them at an appropriate rate for the application
     • Dedicated engineering workstations (EWS)
                                                                                                                                                           - Continuous task runs in the background and is typically used for PLC type operation and motion
     • Multiple operator workstations (OWS)                                                                                                                - Periodic tasks to provide the deterministic time based control for process (Periodic tasks are adjustable down to 2ms)
     • Separate system server to manage client OWS and system services                                                                                     - Event tasks are used for event driven control
              o    Alarms and events
              o    System security                                                                                                                   A Common Data and Information Infrastructure is provided through the use of NetLinx technology and industry standards to create a communications framework. This
              o    Software authorization                                                                                                            framework links all of the system elements together and enables a distributed computing environment with easy data flow throughout the system .
                                                                                                                                                          - At the field level the infrastructure hosts sensors, actuators, drives and other related instrumentation and control devices with industry standard device
     • Optional batch management server
                                                                                                                                                          networks; Foundation Field bus for process devices, DeviceNet for Industrial Control Devices and for non networked devices remote IO modules.
     • Optional data acquisition server                                                                                                                   - The device Networks, Remote IO and Drives connect with the logical control devices through ControlNet, providing the deterministic communications required
                                                                                                                                                          for time based process and high speed discrete control.
  Use a centralized system for applications with multiple operator workstations that can each view the entire system. In addition to                      - Standard Industrial Ethernet is the primary or supervisory network in either simple or fault tolerant configurations connecting the supervisory level system elements
  independent system features, a centralized system includes capabilities such as advanced data collection (historian), complex                           to the control / device level.
  batch, and basic MES interconnectivity to product lines or multiple batch trains.
                                                                                                                                                     Redundant and Fault tolerant capabilities are easily added to the provide the High Availability required by many process applications. The controller platform can be
                                                                                                                                                     implemented to have no single point of failure by adding;
  Centralized System Elements
                                                                                                                                                           - Redundant Processors
       The following listing of IA products is being provided as a typical and can ne used as a guide to define equipment that is required to                                                                         (NOTE: Requires redundancy using V15.5 and 6.5 when available)
                                      configure a system and is not intended to address any specific application.                                          - Fault Tolerant / redundant Networks
                                                                                                                                                           - Fault Tolerant IO

  W orkstations                                                                                                                                      Engineering Workstations provide the system development environment for configuring the controllers, operator interfaces and configurable field devices and developing the
                                    Engineer W orkstation                            Dell w19"/monitor                       1                       application control strategies for the system. Engineering workstations also provide for the system management typically required in networked systems.
                                                                             CPU      Dual Pentium
                                                                      Clock Speed         3.0 Ghz
                                                                                                                                                            - RSLogix 5000 is a full featured editing software, that allows interacting with multiple control strategies (and control languages) concurrently as well as online
                                                                             RAM          2 Gbyte                                                           editing / development without interrupting the process being controlled. The software is based on a combination of ISA-S88 and IEC1131-3 compliant control language
                                                                                          SP2 or                                                            models that enables solving control problems efficiently with the appropriate programming language and instructions.
                                                                Operating System       XP Pro SP2                                                                  Ladder Diagram (LD) – State based (PLC) sequential and motion control
                                    Process Automation Server Pass                   Dell w19"/monitor                     1 to 2
                                                                                                                                                                   Function Block Diagram (FBD) – Continuous process (DCS) and drive loops
                                                                             CPU      Dual Pentium                                                                 Sequential Function Chart (SFC) – Batch operations and equipment sequencing
                                                                      Clock Speed         3.0 Ghz                                                                  Structured Text – (ST) custom control algorithms and custom looping and complex mathematical algorithms
                                                                             RAM          2 Gbyte                                                           - RSView Studio is software used for the development of the operator interface client application (OWS)
                                                                                     W in 2003 Server                                                              Custom Displays using object oriented, drag and drop graphics editor
                                                                Operating System            SP1
                                                                                                                                                                   Standard objects provide quick intuitive interaction with the process being controlled including; faceplates for the human interface, alarming, trending and
                                    Operation W orkStation                           Dell w19"/monitor                    1 to 25                                  reporting.
                                                                            CPU           Pentium                                                                  Custom control using VBA and Active X scripting
                                                                    Clock Speed           2.0 Ghz                                                                  Alarm management to help the operator handle abnormal situations quickly and effectively
                                                                            RAM           512 MB
                                                                Operating System       XP Pro SP2
                                                                                                                                                                   Data logging for trending and Historical data retention

                                                                                                                                                     Operator Workstations provide a distributed interactive view into the process being controlled by the automation system including the controller, smart field devices (FF and
  Supervisory Network                                                                                                                                HART) and 3rd party systems. In Centralized and Distributed system architecture the OWS can be associated with multiple application servers.
                                    Layer 3 Managed Ethernet Switch                 Cisco 2955
                                                                                    NetGear GSM 7224       As required for the Network Topology
                                                                                                                                                          - Custom and standard displays use graphic objects for easily visualization of the operation and navigation to the process control equipment.
                                                                                    Cat 5 cable or Fiber                                                  - The main or top screen or plant overview is a graphic that shows the complete plant / system (including navigation), from which the operator can select or navigate to
                                                                                                                                                          areas of interest. From this graphic an operator can see that the plant is operating within tolerance and maybe have some production data to show how well the
                                    Layer 2 Managed Ethernet Switch                 Cisco 2955                                                            plants operating.
                                                                                    NetGear GSM 7224       As required for the Network Topology
                                                                                                                                                          - From the overview, the different process areas would be identified such as Pre-mix, Batch / Blending, Packaging and if there is a problem (alarm) in any area ie:High
                                                                                    Cat 5 cable or Fiber
                                                                                                                                                          Temp.flow, level, or low filler production rate, it is indicated on the overview by highlighting the area in trouble.
  Controller                                                                                                                                              System wide Alarm Display and Navigation
                                    Supervisory Network Interface                   1756   ENBT or EW EB          1 per Controller Chassis                - When an alarm occurs, the process area that has the problem can be highlighted such that the operator can easily detect that the process is out of tolerance.
                                    Logix Power supply                              1756   PA7x                    1 per controller chassis               Then using a pointing device (touch screen or mouse) rapidly go to the problem by selecting the highlighted Area.
                                    ControlLogix Chassis (4, 7,10, 16 Slot)         1756   Axx                         1 per controller
                                    Logix Processors                                1756   L63               12 non redundant max per system
                                                                                                                                                          - Once at the detailed area graphic all the process units that are located in that production area, such as Premix Area 1 tank A, B, C etc., are shown
                                    System Redundancy Modules                       1757   SRM               1 per redundant controller chassis           - The operator selects the Unit in alarm from his graphic and this will take him to a graphic that shows the details of the Process Unit (Measurements, pumps, valves
                                    Redundancy Module Cable                         1757   SCR xx                    1 per controller pair                etc) if this is a detailed unit screen then the loop that’s in alarm (tank level, temp, etc) will be highlighted.
                                    ControlNet Interfaces (Remote IO)               1756   CNBR                 1 per Remote 31 IO modules                -Standard Control Faceplate objects
                                                                                                                                                                 The operator is able to select a loop and take control of the process to correct the problem (with the proper security level)
  Remote IO
                                    ControlLogix Chassis (4, 7,10, 16 Slot)         1756 Axx                          8 per controller                           From any graphic, you are able to click on a troubled loop device such as a pump, valve etc and open a process FP’s for PID, 2/3 state, ramp soak etc and
                                    Logix Power supply                              1756 PA7x                          1 per chassis                      take control of the loop using the tools provided in the faceplates
                                    ControlNet Interfaces                           1756 CNBR                          1 per chassis                             Change the control to manual and take control of the final element
                                    Digital Input
                                                                                                                                                                 Change the Setpoint, Hi/Lo limits
                                    Digital Output
                                    Analog Input
                                                                                     Standard 1756 IO      Up to 64 IO modules, apx 1024 points                  Trend the PV, SP, and CV of a loop to better visualize the loop operation.
                                                                                                             any mix (unschedule) 128,00 high
                                    Analog Output                                                                                                                Built in Autotuner can be used to establish loop PID parameters.
                                                                                                           speed optimized Discrete (scheduled),
                                    Hart Analog Input                               1756   IF8H                                                           - Operator defined Process Trends
                                    Hart Analog output                              1756   OF8H                                                           - Operator defined Local Historian / Data logging
                                    Industrial Control device bus (Dnet)            1756   DNB                          As required
                                    HSE (Enet) Instrument Network                   1756   ENBT                         As required
                                                                                                                                                     Maintenance Workstations (typically a laptop) are the same software as the Engineering Workstation except is designed to be portable so it can be connected into the system
  Field Device Interfaces                                                                                                                            locally and used to monitor and debug a system problem. When the workstation is introduced into the system, the program that is currently being executed can be uploaded
                                    Foundation Fieldbus Linking Device (CNet)       1788 CN2FF                                                       into the workstation, including and configuration comments. This ensures that the most current code is be used and edited.
                                    Foundation Fieldbus Linking Device (HSE)        1757 FFLD

   Publication PROCES-AP006A-EN-E Nov, 2006

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