PlantPAx Process Automation System

Delivering Plant-Wide Optimization


PlantPAx provides a range
of integrated solutions
delivered through:
Control and I/O
Operator Eectiveness
Engineering and
Configuration Tools
Asset Management
Safety and Critical Control
Batch Management
and Control
Advanced Process Control
Operations Productivity
Industrial Security
2
Utilize Your Process Automation System
to Address Key Market Challenges
As technology continues to drive innovations, the production enterprise must
keep step to remain competitive. Companies must converge their production
disciplines into an integrated plant-wide architecture that better addresses
their key market challenges.
Cultivate INNOVATION with increased
visibility and knowledge capture
Support SUSTAINABILITY with extended product lifecycles,
safer environments, and reduced energy usage
Improve PRODUCTIVITY with continuous improvements
that provide better asset utilization and system performance
Facilitate GLOBALIZATION with extensive global support
capabilities that meet local standards requirements
Drive Plant-wide Optimization
Across Multiple Enterprises
By converging your plant oor with your enterprise IT systems, your people,
processes and technology, are transformed into assets that help you achieve
higher levels of business performance. The Rockwell Automation PlantPAx
process automation system helps you do just that.
PlantPAx combines the plant-wide control technologies and unmatched
scalability of Integrated Architecture with all the core capabilities expected
in a world-class distributed control system (DCS).
Based on open communication standards and leveraging EtherNet/IP as its
backbone, PlantPAx makes real-time information readily available throughout
the organization for better business decisions.

Gain a Competitive
Advantage
The PlantPAx process automation system
provides the technology and solutions to
help you achieve a competitive advantage.
In addition to delivering multi-disciplined
functionality for maximum reach, PlantPAx
also delivers adaptability to changing
requirements. It offers you easy design,
deployment and improved visibility.
Plant and Production Operators
True plant-wide control for reduced total cost of ownership
Increased availability for greater production performance
Real-time intelligence for better business decisions
Skid and Process Equipment Builders
Right-sized designs to save costs
Easy integration to existing plant control systems
Eciency tools for faster time to market
Solution Providers / System Integrators
Comprehensive suite of design and development tools
to increase engineering eciencies
Increased technical competency through training,
events, and support access
Greater customer satisfaction
We had a very clear view of
what we wanteda distributed
control system which runs off a
set of servers integrated into our
general IT infrastructure.
Andy Ellams, Process
Development Manager,
PZ Cussons
We have been very successful in applying
PlantPAx to numerous applications, includ-
ing Advanced Process Control. As a member
of the Process Systems Integrator Program
we distinguish ourselves from non-members
because Rockwell Automation endorses our
ability to deliver quality PlantPAx systems
to mutual clients. This gives our clients the
assurance and comfort of working with
technically competent and experienced
solution providers and has increased our
client satisfaction throughout the project
and system lifecycles
Steve Malyszko, President
Malisko Engineering, Inc.
3
 A Wealth of Capabilities in an Integrated Solution
PlantPAx is the only process automation system capable of managing the entire range of automation
applications, including motion, safety and drive systems.
The scalability of the PlantPAx system, combined with the domain expertise of Rockwell Automation,
enables you to address production issues with real-time plant-wide intelligence, helping you respond
quickly and cost-effectively to market demands.

Engineering and Configuration

Helps shorten development time and
minimize human error
Consolidated Engineering Environment
Single starting point for system configuration and
tools for library management and bulk system
engineering save time

Modular Object Library

Logic and HMI objects co-developed and
co-deployed shorten development time

Defined System Architectures

Minimizes risk of incorrectly sized systems
Logix5562 ETHERNET ANALOG INPUT AC INTPUT

and ensures system performance

POWER RUN I/O ST 0 1 2 3 4 5 6 7
Module Module Module Module Module Module Module
FLT 0 1 2 3 4 5 6 7 O ST 0 1 2 3 4 5 6 7 O Module Status Status Status Status Status Status Status
FORCE RS232 Status
ST 8 9 10 1112131415 K ST 8 9 10 1112131415 K
DeviceNet Network Network Network Network Network Network Network
BAT OK FLT 8 9 10 1112131415 Status Status Status Status Status Status Status
Status
NODE: NODE: NODE: NODE: NODE: NODE: NODE:
RUN REM PROG RXD TXD OK DIAGNOSTIC DIAGNOSTIC DeviceBus
Status

24VDC 24VDC 120V

Relay 120 VAC 220 VAC Sink Source 220VAC
Output Input Input 220 VAC Input
Input Output Output
1734-ADNX
0 4 0 0 0 4 0 4 0 0

1 5 1 1 1 5 1 5 1 1

2 6 2 2 2 6 2 6 2 2

3 7 3 3 3 7 3 7 3 3
1734 1734 1734 1734 1734 1734 1734
OW4 IA4 IM4 IB8 OB8E OA4 IM4

B A

Control and I/O

Offers the most modern infrastructure
for the most cost effective design
Scalable Controller Portfolio
Align process areas from 10 points to thousands
across the platform
Robust Network Infrastructure
Demonstrated performance leveraging CISCO
technology and EtherNet/IP with redundancy
options at every level
Comprehensive Connectivity
The broadest range of traditional I/O and
intelligent devices
Safety and Critical Control
Reduces your economic risk by protecting
only critical assets
High Availability Process Control
High availability solutions from redundant I/O
to redundant controllers, resilient networks to
redundant HMI servers
Scalable Process Safety
Integrated basic process control system (BPCS)
and scalable SIS solutions, including Triple Modular
Redundancy (TMR) for the highest availability

4
 Operator Eectiveness
Helps facilitate operator performance
with easy-to-interpret process information
Integrated Visualization
Intuitive displays, objects, and faceplates with
integrated diagnostics streamline operator response

Alarm and Event Management

Provides a single, integrated set of alarm information

Decision Support Tools

Dashboards help identify opportunities for
continuous improvement

POWER
Logix5562

RUN I/O
ETHERNET
ST
ANALOG INPUT
0 1 2 3 4 5 6 7
AC INTPUT
Scalable Architecture
FLT 0 1 2 3 4 5 6 7 O ST 0 1 2 3 4 5 6 7 O
FORCE RS232
ST 8 9 10 1112131415 K ST 8 9 10 1112131415 K

BAT OK FLT 8 9 10 1112131415

Solutions for on-process, mobile, and stand-alone

RUN REM PROG RXD TXD OK DIAGNOSTIC DIAGNOSTIC

B A

applications up to large distributed systems

deployed traditionally or virtualized

Asset Management
and System Maintenance
Helps ensure process uptime through
improved asset performance management
and predictive maintenance
Instrumentation
Comprehensive device management enabled by
industry standards

Devices
Variable frequency drives and intelligent motor
control devices as native components

5
 Batch Management and Control
Offers the flexibility to respond to
external pressures such as regulatory compliance,
yield optimization and production agility

Scalable Platform
From unit scale to highly complex
integrated batch solutions

Native ISA-88 Structure

Simplify change management and
regulatory compliance

Integrated Analysis Tools

Batch reports, material usage, genealogy,
and solutions to optimize batch production

Logix5562 ETHERNET ANALOG INPUT AC INTPUT

POWER RUN I/O ST 0 1 2 3 4 5 6 7

Operations Productivity
Module Module Module Module Module Module Module
FLT 0 1 2 3 4 5 6 7 O ST 0 1 2 3 4 5 6 7 O Module Status Status Status Status Status Status Status
FORCE RS232 Status
ST 8 9 10 1112131415 K ST 8 9 10 1112131415 K
DeviceNet Network Network Network Network Network Network Network
BAT OK FLT 8 9 10 1112131415 Status Status Status Status Status Status Status
Status
NODE: NODE: NODE: NODE: NODE: NODE: NODE:
RUN REM PROG RXD TXD OK DIAGNOSTIC DIAGNOSTIC DeviceBus
Status

24VDC 24VDC 120V

Relay 120 VAC 220 VAC Sink Source 220VAC
Output Input Input 220 VAC Input
Input Output Output
1734-ADNX
0 4 0 0 0 4 0 4 0 0

1 5 1 1 1 5 1 5 1 1

2 6 2 2 2 6 2 6 2 2

3 7 3 3 3 7 3 7 3 3
1734 1734 1734 1734 1734 1734 1734
OW4 IA4 IM4 IB8 OB8E OA4 IM4

Puts actionable information into

B A

the hands of decision makers quickly

Scalable Data Collection

Chassis-based, plant-wide or enterprise-wide historian for
collecting real-time data at the source

Decision Support Portal

Track production KPIs to manage cost, quality, and resources
to help optimize operations

6
 Advanced Process Control
Delivers proven economic gains through increased production,
reduced costs, improved product quality and reduced environmental risks
Broadest Solution Portfolio
From basic regulatory control to fuzzy logic and soft sensors to
model predictive control
Scalable Optimization
From single loop in the controller to plant-wide optimization at
the supervisory layer

Logix5562 ETHERNET ANALOG INPUT AC INTPUT

POWER RUN I/O ST 0 1 2 3 4 5 6 7
FLT 0 1 2 3 4 5 6 7 O ST 0 1 2 3 4 5 6 7 O
FORCE RS232
ST 8 9 10 1112131415 K ST 8 9 10 1112131415 K

BAT OK FLT 8 9 10 1112131415

RUN REM PROG RXD TXD OK DIAGNOSTIC DIAGNOSTIC

B A

Industrial Security
Addresses risks to help protect people, assets and information
from accidental and malicious threats

Safe and Reliable Operations

Control system architecture with layered security to help maintain operational integrity under threat

Assets and Information Protection

Product and system features to help control access and limit information exposure

Government and Standards Alignment

Responsible disclosure with control system solutions that follow global standards

7
 Consumer Industries
One plant-wide control architecture enables plant-wide optimization
from raw materials, primary processing, packaging and warehousing.

Plant-Wide Control
Drives Total Cost of Ownership (TCO) savings
One platform, one system with common configuration
Multi-disciplined control process, discrete, motion, safety and power
Leverages EtherNet/ IP from the plant oor to the enterprise
linking production information to business systems

Manufacturing Intelligence
Enables continuous process improvement
Information-enabled DCS supports lean Six Sigma programs
Real time intelligence enables faster decision making

Batch Management
Allows for modular designs providing savings
on engineering and maintenance costs
Enables control strategies that support exible production capabilities
Enhanced material tracking and tracing for regulation and standards
requirements
Defined repeatability to achieve golden batch

OEM Scalable
Provides cost-effective skid design, development and deployment
Easy integration of skids to DCS
Rapid field device integration
Supports multi-vendor integration
Reduced training requirements

Rockwell Automations batch solution

is giving us the ability and flexibility to
meet our very aggressive schedules.
Jim Hasler, Silica Treatment
Development Centre Leader,
Cabot Corporation

8
9
 Resource Industries
Premier integration of power control components on industrial EtherNet/IP
network, which includes variable frequency drives and motor control centers,
provides reduced system lifecycle costs. Additionally, real-time access to device
information improves maintenance and troubleshooting capabilities and helps
lower energy consumption.

Operational Excellence
Provides critical asset health and performance information
for optimization
Integrating control, power, and safety enables asset performance management
Diagnostic data can trigger manual or automatic intervention before
any unplanned shutdown
Immediate access to information enables quicker troubleshooting and response times
World leading advance process control and condition monitoring drive energy
eciencies and reduced variability for cost savings

Security
Protects people, assets, and information from accidental
or malicious threats
Intellectual property protection through standard system capabilities
Government and standards alignment to fulfill independent requirements
Control system architecture with layered security to help maintain operational integrity
under threat

High Availability and Safety

Provides protection for personnel, equipment, production
and the environment
High availability and redundancy throughout the architecture for demanding 24 x 7
critical applications
Scalable safety solutions from SIL1 to SIL3, including TMR
Focused on availability, uptime, maintainability and repeatability

Sustainability
Provides cleaner, safer and more energy ecient operations
to help you achieve your business goals
Easy integration of PlantPAx, with energy monitoring control and reporting tools
Vital data helps maximize asset availability, utilization and eciency, which means more
production uptime, reduced raw material use and optimized, ecient energy use
Continuous emission monitoring to help ensure active compliance

10
11
 Skid and Process
Equipment Solutions
Scalable, Cost-Eective and Easily Integrated
Rockwell Automation and its partners help lower
your Total Cost to Design, Develop and DeliverSM
equipment. Our PlantPAx libraries and productivity
toolkits provide the technology and economic
advantages required. We can help you assess and
quantify the value realized by choosing us as your
preferred process automation partner.
The ability to go from discrete wiring
to a network implementation has not
only helped achieve significant savings
in wiring, but also has helped reduce
installation costs. In one recent project,
we were able to eliminate more than
600,000 feet of wiring while cutting
our installation time in half.
Mike Hilton, Director of Electrical
Instrumentation and Controls,
Industrial Furnace Company

Reduce Short-Term Costs

System resides on the skid and ships fully tested
and operational
Interfaces exist to other supplier systems
Speed design and integration through robust
process library
Simplify remote monitoring and support through
use of unmodified Ethernet
Maximize uptime and customer satisfaction

Protect Intellectual Property

Because of its scalability and designed openness, our
OEM solutions can be connected to other systems
without exposing your intellectual property
Deal directly with the end user no need to share
your proprietary control algorithms with other
suppliers or their integrators
Create long term support contracts with end users
instead of relinquishing support to other suppliers

Reduce Your Total Cost to

Design, Develop and Deliver
By taking advantage of our systems, products and
services you will be better equipped to react quickly
to change while continuously improving profitability.
We can help reduce the cost of:
Quotation Purchase
Engineering Training
Commissioning Warranty Service
Installation Design Updates
12
Migration Solutions
Migration services from Rockwell Automation help you
expertly and quickly migrate to newer technologies while
minimizing downtime and maximizing operational success.
They help you achieve productivity gains, lessen the risk of
maintaining legacy equipment, and allow you to migrate at a
pace that is comfortable for you. And most importantly, they are
instrumental in driving system lifecycle cost savings.
We have expert migration solutions for many legacy DCS
systems. This includes ease-of-migration tools such as scanners,
cables, wiring harnesses, database conversion tools, and more.

WE CAN HELP YOU GO TO HERE . . .

FROM HERE . . .

Easy access to plant and

Lack of visibility to
production data for better
production data
decision making

Uncertain parts and service Quickest response to

sourcing market demands

Open, integrated architecture

Limited network options
for increased flexibility

Product backed by the

Weakening technical service
outstanding support services
and high repair costs
of Rockwell Automation

Re-use of engineering
Unscheduled downtime risks practices to reduce
and lengthy startups development time and costs
associated with startups

Maximizing returns from

Questionable reliability of existing assets through
older electronics improved control and
monitoring

Single environment for

Old equipment that
integrated motion, process,
lacks production eciency
and safety for plant-wide
and flexibility
optimization

13
 Solutions & Services
Bringing You a World of Experience
Across industries and processes, you can leverage
our global experience and partner resources to tailor
solutions and services capabilities to meet your needs.
Rockwell Automation understands that a profitable, safe
and sustainable operation is your goal. As your partner, we
offer industry and technology-specific expertise to address
your unique challenges and meet your goals.
Our services include:
Asset Management - 80 countries

Consulting & Assessment - 20 languages

Engineered Packages & Panels - 18 ISO-certified repair centers
Integration & Turnkey Services
- 9 exchange hubs
Main Automation Contractor (MAC)
Maintenance & Repair - 6 remote support centers
Migration Services - Single site or multi-site delivery
Online & Phone Support
- Average 13+ years
On-Site Services industry experience
Systems Design
Training
Our commitment to you is to help reduce
project risk and provide solutions specific to your
needs executed globally and supported locally.

Reduce your project risk

Originate Initiate Plan

Pre-project planning Develop project charter Collect requirements
Front End Engineering Identify stakeholders Define activities
Customer & Design (FEED) Develop project
management plan
(cost, quality, risk,
communication, schedule,
scope and change control,
procurement and stang)

14
 Optimize Your Operation
As your partner, we start with an important
step often overlooked in todays competitive
business world: we listen, to learn about your
company, your issues and your goals for
today, tomorrow and the future. After we
understand your unique situation, we draw on
our global pool of in-house experience and
partner resources to deliver tailored, repeatable,
scalable and maintainable solutions.

Protect Your Investment

By leveraging our global infrastructure of
support centers and subject matter experts,
were here to help you protect your automation
investment. Beyond providing you peace
of mind, as we help you keep your plant
running, well assess your entire operation and
recommend the right mix of services to help
maximize productivity, optimize plant assets
and improve your overall financial performance.

Solutions & Services for any stage of your automation lifecycle

Execution & Control Close Operate & Improve

Quality assurance Close project activities Parts management
Manage resources Capture lessons learned Preventive maintenance
Communicate and report Survey customer satisfaction Training
Monitor and control risks Transfer to operations / Embedded engineer
Manage and control support teams
(resources, scope, schedule and costs)

15
The Power of Collaboration
When you choose Rockwell Automation, you also tap into the power of our PartnerNetwork program
a framework of well-managed relationships based on your needs. Our program provides you with access
to a local, regional and global network of best-in-class companies including distributors, system integrators,
machine builders, alliances and complementary product providers.
The keystone of our PartnerNetwork is collaboration that allows a seamless relationship with you, built on
mutual trust and shared business values.

PartnerNetwork
Business Enterprise Sales & Solutions Products & Technologies

Strategic Alliances Distributors Product Refe

Reference
f rence
Enterprise Solution Partners Solution Providers T
Technology Licensing
Licensing
Machine Builders
For more information about our
process automation solutions, please visit:
http://www.rockwellautomation.com/solutions/process/

Rockwell Automation, Inc. (NYSE:ROK), the worlds largest company dedicated to industrial automation, makes its customers more
productive and the world more sustainable. Throughout the world, our agship Allen-Bradley and Rockwell Software product
brands are recognized for innovation and excellence.

Follow ROKAutomation on Facebook & Twitter. Connect with us on Linkedin.

PlantPAx, Integrated Architecture, Listen. Think. Solve, Total Cost to Design, Develop and Deliver, and PartnerNetwork are trademarks of Rockwell Automation, Inc..

Publication PROCES-BROO1D-EN-P August 2011 Copyright 2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Supersedes Publication XXXX-BR00XX-XX-P Month 20XX