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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
• 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
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
• 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
• Configuration/Setup, Setup Basic Function • 12,288 I/O points
Blocks, Design Power circuit, Design Network • 1500 Loops
Topologies, Setup Link Master, Configure
• Scheduled as an I/O rack
• H1 network requires power supply, power 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)
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
Change the Setpoint, Hi/Lo limits
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