Reference Manual · Publication PROCES-RM001 · Rockwell Automation

PlantPAx DCS System Release 4.5/4.6 Reference Manual

This reference manual covers the PlantPAx Distributed Control System for System Release 4.5 and 4.6. It documents system architecture classes, sizing rules, server and workstation hardware requirements, controller selection and CPU utilization guidelines, alarm system recommendations, field device integration, and maintenance procedures. Engineers and system integrators use this manual alongside the PlantPAx Selection Guide (PROCES-SG001) and the PlantPAx System Estimator to configure and size a PlantPAx system.

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120 Max OWS Clients (Distributed)
10 servers or redundan… Max PASS Servers
≤ 2 seconds Display Callup CSA
1000 alarms timestampe… Alarm Burst CSA

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Specifications

Critical System Attribute (CSA) Performance Indicators

Display callup (paint time) Non-cached display ready for operator use within 2 seconds
Display update Control information updates within 1 second
Steady state alarm time 20 alarms/second timestamped within 1 second
Alarm burst time 1000 alarms all timestamped within 3 seconds
Recovery System element returns to full operation within 5 minutes after restoration
Operator-initiated control Action loaded to controller and feedback returned within 2 seconds
Batch server: operator action time Operator batch command acted on by controller within 1 second
Batch server: server action time Server batch command acted on by controller within 1 second
Batch server: controller action time Batch status events display on OWS within 1 second

PASS Virtual Requirements

vCPU 4 vCPU
vRAM 8 GB minimum
vHard Disk 60 GB
Resource pool High priority
Operating system Windows Server 2016, 64-bit

PASS Traditional Requirements

Processor Intel Xeon Multicore (4 cores or greater), 2.40 GHz minimum
RAM 8 GB minimum
PASS-C processor (small/medium systems) Intel Xeon E-31270 v5, 3.60 GHz minimum
PASS-C RAM 32 GB minimum
PASS-C scope Systems with fewer than 2000 I/O points
Operating system Windows Server 2016, 64-bit

EWS Virtual Requirements

vCPU 2 vCPU
vRAM 4 GB minimum
vHard Disk 100 GB
Resource pool Normal priority
Operating system Windows 10, 64-bit

OWS Virtual Requirements

vCPU 2 vCPU
vRAM 4 GB minimum
vHard Disk 40 GB
Resource pool High priority
Operating system Windows 10, 64-bit

AppServ-OWS Virtual Requirements

vCPU 8 vCPU
vRAM 16 GB minimum
vHard Disk 60 GB
Max thin clients 10 FactoryTalk View SE clients per application server
Operating system Windows Server 2016, 64-bit

AppServ-EWS Virtual Requirements

vCPU 4 vCPU
vRAM 8 GB minimum
vHard Disk 100 GB
Max thin clients 5 FactoryTalk View SE clients per application server
Operating system Windows Server 2016, 64-bit

Simplex ControlLogix Controller Sizing

1756-L71 user memory / max I/O / max control strategies 2 MB / 375 I/O / 60 strategies
1756-L72 user memory / max I/O / max control strategies 4 MB / 750 I/O / 125 strategies
1756-L73 user memory / max I/O / max control strategies 8 MB / 1500 I/O / 250 strategies
1756-L74 user memory / max I/O / max control strategies 16 MB / 2250 I/O / 450 strategies
1756-L75 user memory / max I/O / max control strategies 32 MB / 2250 I/O / 450 strategies
Tags/sec delivered to data server (all models) 20,000 maximum (10,000 for L71)

Redundant ControlLogix Controller Sizing

1756-L73 user memory / max I/O / max control strategies 8 MB / 750 I/O / 125 strategies
1756-L74 user memory / max I/O / max control strategies 16 MB / 1500 I/O / 250 strategies
1756-L75 user memory / max I/O / max control strategies 32 MB / 2250 I/O / 450 strategies
Tags/sec delivered to data server (all models) 20,000 maximum

Skid-based CompactLogix Controller Sizing

1769-L24ER-QBFC1B user memory / max I/O / max strategies 0.75 MB / 80 I/O / 10 strategies
1769-L19ER-BB1 user memory / max I/O / max strategies 1.0 MB / 125 I/O / 15 strategies
1769-L33ER user memory / max I/O / max strategies 2.0 MB / 250 I/O / 30 strategies
1769-L36ERM user memory / max I/O / max strategies 3.0 MB / 350 I/O / 45 strategies
Tags/sec delivered to data server (all skid models) 3,000 maximum

Controller Memory Recommendations

Simplex, outside production environment 50% free memory; 50% free CPU time
Simplex, in production environment 25% free memory; 25% free CPU time
Redundant, outside production environment >50% free memory; 50% free CPU time
Redundant, in production environment >50% free memory; 50% free CPU time

PlantPAx Software Component Versions (Release 4.6)

Studio 5000 Logix Designer Version 31.x
Studio 5000 Architect Version 4.x
FactoryTalk View Version 11.x
FactoryTalk Batch Version 13.x
FactoryTalk AssetCentre Version 9.x
FactoryTalk VantagePoint Version 8.x
FactoryTalk Historian Version 6.x

Communication Protocols

Supported industrial networks and field buses for the products covered by this publication.

EtherNet/IP Controller Ethernet interface: 1756-EN2TR for direct DLR connection, 1756-EN2TP for direct PRP connection, otherwise 1756-EN2T or 1756-EN2F (no DLR support) ControlNet ControlNet interface, if applicable: 1756-CN2, 1756-CN2R, 1756-CNB, or 1756-CNBR DeviceNet Field device integration supported with DeviceNet communication options documented in Chapter 6 HART Field device integration via HART analog I/O; ControlLogix HART analog I/O modules referenced (publication 1756-UM533) FOUNDATION Fieldbus Supported via 1788-EN2FFR and 1788-CN2FFR linking devices PROFIBUS PA Supported via 1788-EN2PAR and 1788-CN2PAR linking devices

Document Contents

Full PDF covers the following topics in detail:

  • Preface
  • Chapter 1: System Architecture Overview
  • Chapter 2: System Element Recommendations
  • Chapter 3: System Application Recommendations
  • Chapter 4: Alarm System Recommendations
  • Chapter 5: Infrastructure Recommendations
  • Chapter 6: Field Device Integration Recommendations
  • Chapter 7: Batch Management and Control Recommendations
  • Chapter 8: Information Management Recommendations
  • Chapter 9: Maintenance Recommendations
  • Appendix A: Verify and Monitor Your System Health
  • Appendix B: System Software Components

Frequently Asked Questions

Which PlantPAx system releases does PROCES-RM001 apply to?
This manual applies to PlantPAx System Release 4.5 and 4.6. For PlantPAx System Release 5.0, Rockwell Automation directs users to publication PROCES-UM100.
What are the four PlantPAx architecture classes described in this manual?
The four architecture classes are: Skid (skid controller with PanelView for monitoring), Station (single workstation acting as PASS, OWS, and EWS), Distributed Single Server (one PASS server supporting multiple OWSs and EWSs), and Distributed Multiple Servers (multiple PASS servers supporting up to 120 OWS clients).
What controllers are supported for redundant configurations in PlantPAx Release 4.6?
Redundant configurations use ControlLogix 1756-L73, 1756-L74, or 1756-L75 controllers paired with a 1756-RM2 redundancy module and fiber media. Each redundant chassis must have the same number of slots, modules in the same slots, and matching redundancy firmware revisions.
What CPU utilization limits does this manual recommend for simplex and redundant controllers?
In the production environment, the manual recommends 25% free memory and 25% free CPU time for simplex controllers, and more than 50% free memory and 50% free CPU time for redundant controllers. Outside the production environment, simplex controllers should keep 50% free memory and 50% free CPU time.
What task configuration rules apply to PlantPAx controllers?
Controllers must use periodic tasks only. Continuous tasks must be deleted. Periodic tasks should have unique priorities, with faster tasks assigned lower priority numbers (higher execution priority). The manual recommends no more than three periodic tasks for optimum CPU performance, and estimates execution overhead at 1000 microseconds per task for system sizing.
What software components are hosted on the Process Automation System Server (PASS)?
The PASS hosts the FactoryTalk Network Directory server, FactoryTalk Activation server, FactoryTalk View HMI server, FactoryTalk View Data server, and FactoryTalk View Alarm and Event server. Optionally, it can host FactoryTalk Batch client software when a Batch Application server is in use.
What field device network protocols does this manual cover for integration with PlantPAx?
Chapter 6 covers EtherNet/IP, ControlNet, DeviceNet, HART, FOUNDATION Fieldbus, and PROFIBUS PA recommendations and communication options, as well as motor control center (MCC) integration recommendations.

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