Selection Guide · Publication PROCES-SG001 · Rockwell Automation

PlantPAx DCS Selection Guide

System-architecture and component selection guide for the Allen-Bradley PlantPAx Distributed Control System (DCS) on ControlLogix 5570 / 5580 / 5590 and CompactLogix 5380 platforms. Walks through every high-level decision that must come before equipment purchase: PlantPAx vs. plain Logix, system-class sizing (Class 1 / 2 / 3 by loop count and plant size), controller selection (standard vs. Process variants, redundant vs. non-redundant), network topology (linear / DLR ring / multi-segment), HMI strategy (FactoryTalk View SE distributed vs. networked), FactoryTalk Historian and AssetCentre integration, batch and recipe management with FactoryTalk Batch, alarm management strategy with FactoryTalk Alarms & Events, security architecture with CIP Security and FactoryTalk Security, and software bundle / licensing summary. Companion to the hands-on instruction references PROCES-RM002 (P_ AOI library), PROCES-RM215 (native process instructions), and PROCES-RM013 (P_ AOI internal logic).

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PROCES-SG001 Publication
Class 1, 2, 3 Sizing tiers
5570, 5580, 5590 ControlLogix
Architects + EPCs Audience

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Catalog Number Format

How to read an Allen-Bradley PROCES catalog number. Each position encodes a specific configuration attribute.

Position
Meaning
Example
PROCES-SG001
Rockwell publication number — Selection Guide for the PlantPAx DCS
PROCES-SG001 (current revision)

Document Contents

Full PDF covers the following topics in detail:

  • PlantPAx system architecture overview, component map, and integration touchpoints
  • Sizing tiers (Class 1 / 2 / 3) — how to pick the right tier for plant size, loop count, and operator workload
  • Controller selection decision tree: standard vs. Process variant (1756-L8xEP, 5069-L3xxERMS), redundancy yes/no
  • Network topology options: linear, Device Level Ring (DLR), multi-segment / aggregated, plant-wide segmentation
  • HMI strategy: FactoryTalk View SE distributed servers vs. network-station deployment
  • FactoryTalk Historian SE / Vantagepoint and AssetCentre integration architecture
  • Batch and recipe: FactoryTalk Batch architecture for ISA-88 batch and SFC sequencing
  • Alarm management: FactoryTalk Alarms & Events server placement and ISA-18.2 conformance
  • Security architecture: CIP Security on the controller, FactoryTalk Security on HMI, IEC 62443 mapping
  • Software bundles and licensing: PlantPAx system bundles, per-tag and per-server pricing models
  • Reference architecture diagrams for each system class

Frequently Asked Questions

When should I choose PlantPAx over plain ControlLogix?
Choose PlantPAx when the application has more than ~30 process loops, requires consistent operator faceplates and alarm management across multiple HMI stations, needs FactoryTalk Historian or Batch integration, or operates under standards that mandate ISA-18.2 alarm management or IEC 62443 cyber security. Plain ControlLogix is cheaper and adequate for machine control or small-skid applications where the PlantPAx framework adds more complexity than it returns. PROCES-SG001 includes a detailed decision tree.
What are the differences between Class 1, 2, and 3 PlantPAx systems?
System classes are sizing tiers. Class 1 is small (single ControlLogix chassis, single HMI station, ~50 loops, no redundancy). Class 2 is mid-size with multiple controllers, redundant HMI, FactoryTalk Historian, ~250 loops. Class 3 is full plant-wide with redundant controllers, multiple HMI servers, asset management integration, thousands of loops, batch and recipe management. The selection guide walks through specific component lists for each class.
What is a Process controller variant (1756-L85EP, 5069-L380ERMS)?
Process variants are standard ControlLogix 5580 and CompactLogix 5380 controllers pre-loaded with the PlantPAx process task template, memory partitioned for the process libraries, and FactoryTalk Historian tag publishing pre-wired. Functionally they run the same firmware as the standard controllers but ship configured for PlantPAx out of the box, saving multiple hours of project-template configuration.
Do I need controller redundancy for PlantPAx?
Not always. Redundancy adds significant cost and complexity but is strongly recommended for continuous process applications where any controller restart would disrupt critical loops. Batch, discrete, and utility applications often run non-redundant. PROCES-SG001 covers the redundancy/availability trade-off in detail along with the 1756-RM2/RM3 redundancy module options for ControlLogix 5570/5580 and the integrated Logix SIS redundancy on ControlLogix 5590.
How does CIP Security and IEC 62443 fit into the architecture?
CIP Security adds authentication, integrity, and confidentiality at the EtherNet/IP protocol level — supported on ControlLogix 5580 and 5590 controllers. FactoryTalk Security handles user authentication and access control at the application layer. Together they map onto IEC 62443 zone-and-conduit boundaries. The selection guide includes reference architectures showing where to place certificate authorities, AD integration points, and trust boundaries between zones.

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