User Manual · Publication PROCES-UM100 · Rockwell Automation

PlantPAx DCS Configuration & Implementation User Manual 5.40

This user manual covers configuration and implementation of the PlantPAx Distributed Control System at System Release 5.40. It provides step-by-step instructions for sizing the system, configuring the Process Automation System Server (PASS or PASS-C), designing network infrastructure, developing process applications, and managing historical data and batch operations. Smaller systems (typically less than 2000 I/O points) use a consolidated PASS-C. Larger, distributed systems use one or more PASS servers.

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5.40 System Release
< 2000 I/O points Small System Threshold
≤ 2 seconds Display Callup Target
2000 alarms within 3 s… Alarm Burst Timestamping

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Specifications

Critical System Attribute Performance Indicators

Display callup (paint time) Non-cached operating display ready for operator use within 2 seconds
Display update Control information updates within 1 second
Steady state alarm time Alarms at 20 per second are timestamped within 1 second
Alarm burst time All alarms in a burst of 2000 alarms are timestamped within 3 seconds
Recovery System element returns to full operation within 5 minutes of restoration
Operator-initiated control Actions loaded into controller with operator feedback within 2 seconds
Batch server: operator action time Operator batch command acted on by controller in 1 second
Batch server: server action time Server batch command acted on by controller in 1 second
Batch server: controller action time Batch status events display on operator workstation within 1 second

PASS-C Server Components (Smaller Systems)

FactoryTalk Directory Included
FactoryTalk Activation server Included
FactoryTalk Security Included
HMI server Included
Data server Included
Alarm and Event server Included
SQL server Included
FactoryTalk Historian server Included
FactoryTalk AssetCentre server Included

Domain vs. Workgroup Configuration

Workgroup maximum computers 10 or fewer
Domain controller minimum At least one per parent/root/child domain
Domain controllers for fault tolerance At least two
Domain controller OS Windows Server 2022 (forest and domain functional level)
Roles installed on domain controller Active Directory Domain Services, DHCP Server, DNS Server

Communication Protocols

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

EtherNet/IP Redundant PRP, resilient DLR, and simplex star topologies are documented OPC UA OPC UA data server on the PASS; FactoryTalk Linx OPC UA Connector documented HART Field device integration supported on process controllers PROFIBUS PA Field device integration supported on process controllers FOUNDATION Fieldbus Field device integration supported on process controllers IEC 61850 Electrical protection device integration supported CIP Security Documented in PlantPAx security architecture appendix NTP / PTP Windows NTP client configuration and NTP to PTP clock conversion are documented

Document Contents

Full PDF covers the following topics in detail:

  • Preface: publication overview, firmware/AOP/EDS downloads, summary of changes, additional resources
  • Chapter 1 - System Workflow: sizing with PlantPAx System Estimator, PASS-C vs. PASS selection, system verification, Critical System Attributes
  • Chapter 2 - Domain or Workgroup: primary and additional domain controller setup, Active Directory, DHCP, DNS, group policies, role/area/user creation, Windows Workgroup configuration
  • Chapter 3 - Process Automation System Server: PASS configuration, FactoryTalk components, HMI server, alarms and events, data servers, DataLogPro, redundant server considerations, runtime security
  • Chapter 4 - Network Infrastructure: VLAN recommendations, redundant PRP topology, resilient DLR topology, simplex star topology, switch configuration, time synchronization, PTP configuration
  • Chapter 5 - Process Controller Features: PlantPAx Process Objects, Add-On Instructions, controller properties, PlantPAx task model, controller-to-controller communication, OPC UA, field device integration, alarm types, HMI displays
  • Chapter 6 - Use ACM to Create an Application: project planning, example application development, adding controllers/devices/hardware bus objects/control strategies, alarm groups, generating controller and graphics files
  • Chapter 7 - Modifying an Existing PlantPAx System: Studio 5000 Logix Designer and FactoryTalk View SE templates, editing tags/alarms/historian points/HMI displays
  • Chapter 8 - Asset Management: FactoryTalk AssetCentre, asset inventory, audit logs, backup scheduling, disaster recovery, retention policy, system storage rates
  • Chapter 9 - Historical Data: historian collective configuration, PI buffering, PI Performance Monitor, historian data collection, historian asset framework, tools for creating historian tags
  • Chapter 10 - Batch Management: Logix Batch and SequenceManager, SequenceManager Controls, FactoryTalk Batch, redundant controller considerations
  • Chapter 11 - Automatic Diagnostics: configuring automatic diagnostics on FactoryTalk View SE
  • Appendix A - PlantPAx Security Certification: security architecture, trusted zones, certificate authority, security feature checklists, VLAN recommendations, CIP Security
  • Appendix B - Firewall Configurations: common ports, Rockwell Automation TCP/UDP ports
  • Appendix C - PlantPAx Deployment Recommendations and Verification Tool: design recommendations, system infrastructure, server/workstation checks, system architecture, PASS tab, controller tabs
  • Appendix D - PlantPAx Troubleshooting Scenarios: HMI communication lost, slow HMI display access
  • Appendix E - FactoryTalk Optix: raP_5_30_Libraries user guide, library structure, project configuration, E-Signature, audit logging, security groups
  • Appendix F - FactoryTalk Optix E-Signature User Guide: features, components, environment setup, E-Signature configuration, workflow pop-up dialogs, event logging
  • Appendix G - Security Policies: system policies, product policies, computers and groups, network and devices, users and groups, connections

Frequently Asked Questions

What is the difference between a PASS-C and a PASS in a PlantPAx system?
The consolidated Process Automation System Server (PASS-C) is intended for smaller systems, typically with less than 2000 I/O points, where all system software is placed on the PASS-C. The PASS supports larger, distributed systems and is used alongside individual application servers (AppServ), engineering workstations (EWS), and operator workstations (OWS).
When should a Windows Domain be used instead of a Workgroup for PlantPAx?
Rockwell recommends that PlantPAx servers and workstations be members of a Windows domain. Workgroups are supported only for systems with 10 or fewer workstations and servers. Domain configurations provide centralized administration of users, policies, and security, and offer high availability when both primary and secondary domain controllers are used.
What network topologies does the PlantPAx system support?
The PlantPAx system supports a redundant PRP (Parallel Redundancy Protocol) topology, a resilient DLR (Device Level Ring) topology, and a simplex star topology. Each topology is based on system characterization tests.
What are the Critical System Attribute performance targets for a PlantPAx system?
Key targets include: non-cached operating display callup within 2 seconds; display update of control information within 1 second; steady-state alarms at 20 per second timestamped within 1 second; a burst of 2000 alarms timestamped within 3 seconds; system element recovery within 5 minutes; and operator-initiated control feedback within 2 seconds.
What field device protocols can be integrated with PlantPAx process controllers?
The manual documents integration of HART, PROFIBUS PA, FOUNDATION Fieldbus, and electrical protection devices using IEC 61850 on PlantPAx process controllers.
What batch management options are available in PlantPAx System Release 5.40?
Three batch solutions are documented: Logix Batch and SequenceManager (LBSM), SequenceManager Controls, and the FactoryTalk Batch application. The FactoryTalk Batch server also supports operation with redundant controllers, including hold propagation and state composite evaluation.
What tools are available to create and manage historian tags in PlantPAx?
The manual documents three tools for creating historian tags: Application Code Manager (ACM), the PI Builder Add-in for Microsoft Excel, and the PlantPAx Configuration Tool for configuring Asset Framework databases.

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