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INTEGRATED ARCHITECTURE
Saving time and money using Integrated Architecture
from Rockwell Automation
Publication XXX-XXXXX-XX-P – Month 200X — Supersedes Publication XXX-XXXXX-XX-P – May 200X Copyright ©200X Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Publication IA-BR002D-EN-P – April 2005 Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Printed in USA
Supercedes Publications IA-BR002B – EN-P – October 2003 and IA-BR002C-EN-P – January, 2005
INTRODUCTION
Integrated Architecture
For manufacturers, OEMs and Systems Integrators, Integrated Architecture from Rockwell Automation®
is an industrial automation infrastructure providing scalable solutions for the full range of automation
disciplines including sequential, motion, process control, drive control, safety and information.
Unlike traditional control architectures, the Integrated Architecture reduces the customer's total cost of
ownership by using a single control infrastructure for the entire range of factory automation applications,
large or small. This enables Integrated Architecture users to re-use engineering designs and practices to
reduce development time and cost, respond more quickly to customer or market demands, reduce
maintenance costs and downtime and easily gain access to plant and production data from business
systems for better management decision-making.
Integrated Architecture is made possible through the unique combination of enabling technologies including
the Logix control platform, NetLinx Open Network Architecture, View visualization platform and FactoryTalk®
data and information services.
l The Logix control platform provides a range of controller functionality and sizes, enabling the user to
choose the most cost-effective controller for the application. All Logix controllers are programmed
INTEGRATED ARCHITECTURE through a single software package that lets the customer choose ladder, function block, sequential
function chart or structured text languages in which to program. Programming is done in the Logix
Saving time and money using Integrated Architecture controller rather than in separate controllers, significantly reducing design, hardware and
programming costs.
l NetLinx open networks provide a network infrastructure for information flow. NetLinx networks share
a common protocol which enables the seamless flow of information from the smallest plant floor
device to the enterprise business system, without additional programming, helping users increase
flexibility, reduce integration installation costs and increase productivity.
l View visualization platforms provide a scalable, unified suite of operator interface and supervisory-
level monitoring solutions that share the same development software, offering faster development
and implementation, flexibility and lower cost of ownership.
l FactoryTalk is a suite of services embedded in Integrated Architecture components that dramatically

simplifies data production, movement and use. FactoryTalk services give the user the capability to
create a tag only once and reuse it throughout the entire control system. In a FactoryTalk-enabled
system, visualization components share a common tag database with the control platform,
dramatically reducing engineering time and cost spent creating individual tags for controller,
visualization and information level uses and mapping them together.
To help you better understand where and when Integrated Architecture from Rockwell Automation can help
you, sections in this booklet are grouped into segments for Design, Install, Operate, Maintain and Support.
Please contact your local Rockwell Automation sales office or distributor for additional information.
OPERATE
Integrated Improve performance, access information from the entire system
Architecture 3.1 Improve decision making with access to real-time operating information
Saving time and money using 3.2 Simply information access by using an EtherNet/IP® network
Integrated Architecture from Rockwell Automation
3.3 Define graphic displays once and reference them throughout a distributed system
3.4 Match your control network to today's needs; provide simple future expansion without risk
3.5 Assure virtually non-stop monitoring with built-in failure detection and recovery
Contents
3.6 Reduce downtime with diagnostics
DESIGN
3.7 Improve plant reliability through integrated condition monitoring
Save engineering time when designing your control system
3.8 Extending your process control system
1.1 Logix solutions provide maximum value and productivity for all types of applications
3.9 Visualization provides information at the right place
1.2 Logix architecture provides a scalable process control platform
1.3 Programming flexibility and productivity with a choice of languages
MAINTAIN
1.4 Simplify programming with tag-based addressing and automatic creation of structures
Use superior diagnostics, reduce downtime for greater productivity
1.5 Define tags once and reuse them throughout a FactoryTalk-enabled system
1.6 Reduce engineering time by doing electrical design and program development concurrently 4.1 Easy access to diagnose and troubleshoot devices throughout a facility
1.7 Logix program structure reduces engineering and allows for modular code 4.2 Use Auto Device Replacement to reduce repair time
1.8 Streamline HMI development with a common editor 4.3 Audit and manage changes to FactoryTalk-enabled systems
1.9 Collaborate on complex projects and reuse object libraries to build control systems quickly 4.4 Remote diagnostics using Web-based communications
1.10 Save engineering time and cost with Kinetix® Integrated Motion
1.11 Extend the functionality of your DeviceNet® network SUPPORT
Maximize production, reduce training costs, and measure results
INSTALL 5.1 What's your maintenance strategy?
Minimize wiring, enjoy a faster start-up with an integrated control system
2.1 Minimize installation time with a Kinetix Integrated Motion Solution VALIDATION
2.2 Upgrade existing motor control systems Benefits of an integrated control architecture
6.1 Validating the economic and time-saving benefits provided by the Integrated Architecture
DESIGN: Save Engineering Time – 1.1
1.1
Integrated Architecture Solution
Logix controller solutions provide For any manufacturing enterprise to be competitive, it must have the flexibility to develop, produce and
maximum value and productivity deliver products with optimal use of its resources. This effective use of resources requires the integration
and maintenance of the business-level systems with real-time event-driven data.
for all types of applications The Logix controller platform provides a multi-disciplined control with a single controller platform and a
single programming package. You can use the same controllers and the same programming software for all
Logix controller scalability saves time and money. Size the control the applications in your plant, regardless of whether you are doing high speed sequential, motion control,
system as needed for your application. process control or drive systems. This greatly reduces your costs for maintenance, spare parts and training.
Example
Conventional Solution
In the past, different control systems were required for different applications. PLCs and motion controllers
were used for high-speed sequential and motion control on packaging machines, DCS systems for
continuous or batch control, and coordinated drive systems for web handling applications. These separate
control systems required different programming software, different spare parts, training on each system, and
then each system had to communicate with the others to integrate the plant’s data needs.
BENEFITS OVER CONVENTIONAL SOLUTION

l Reduce your inventory by using the same spare parts for sequential, motion, process and drive control
l Reduce the amount of training by using the same hardware and software for all applications
l One software package for all programming
l One solution provides control for all applications
TECHNOLOGY
l RSLogix 5000 programming software
l Highly integrated process, sequential, motion and drive control
1.2
For easier maintenance, these languages all support uploading from the controller. You can connect to a
Logix architecture provides a controller over the network and upload the working project for modification or monitoring, even if you don’t
have the source project on your computer.
scalable process control platform
ControlLogix and ControlNet redundancy provide high control system availability for your process. If a failure
in the primary controller chassis or network occurs, then bumpless control will switch over to the secondary
chassis, allowing your process to keep running.
To remain competitive, process manufacturers must have the flexibility
In addition to an extensive line of I/O module families, FOUNDATION fieldbus™ and HART™ interfaces can be
to integrate changing plant-wide operations. Logix-based control
used to connect to integrate intelligent field devices without standalone multiplexers.
systems make this complex task a simple, lower-cost reality
Example
In the past, customers were forced to buy single-loop controllers for stand-alone process loop applications
and buy largely inflexible DCS systems for larger process control applications. In many cases, they had to
overpay for control systems. Different levels of control capability had to be purchased for different control
areas, usually needing different training, different spare parts inventory and different maintenance schedules
and personnel. Using a DCS for process control also meant a different type of control system was used for
the process area than was used in the rest of the plant.
Logix Solution
Our Integrated Architecture focuses on the entire application and its relationship to other plant-floor
activities. Process capabilities are available across all Logix platforms, so you can use the same control
strategies in a large or small Logix-based system, providing excellent scalability. A ControlLogix system has
the power to handle large process control applications with thousands of I/O points. The exact same type of BENEFITS OVER CONVENTIONAL SOLUTION
control for a smaller system with dozens of I/O points can be provided by a smaller CompactLogix or l Plant-wide control with a single controller platform – and a single programming package!
FlexLogix controller. You can even move routines of code between any of the Logix controllers. This allows l Complete scalability allows the same process strategies to be applied in large and small systems
you to much more cost-effectively control any of your process applications, regardless of the application l Projects can be uploaded from a running controller for easier maintenance
size. And since Logix controllers can also be used for all plant-wide applications – from process control to l Maintenance costs are greatly reduced by using a common architecture throughout your facility
high-speed packaging to coordinated drive systems – the process system is easily integrated with the rest of
the plant.
TECHNOLOGY
For process control, RSLogix 5000 provides a library of built-in process control instructions providing an l Built-in process control instruction set
instruction set similar to what is found in a typical DCS system. Logix supports languages such as Function l RSLogix 5000 Function Block Diagram and Sequential Function Chart editors provide
Block Programming for continuous process applications and Sequential Function Chart and Phase Manager intuitive programming for process control applications
for batching applications. Structured Text is also useful for complex algorithms such as efficiency l Easy to implement ControlLogix redundancy solution for high availability
calculations. ActiveX faceplates make it easy to quickly set up operator interfaces. l Logix systems have interfaces to process networks such as FOUNDATION fieldbus and HART
1.1
1.3
Using the right language reduces program complexity,
Programming flexibility and improves development, reduces costs
(see Validation section 6.1 for details)
productivity with a choice Sequential Function Chart
of languages Function Block Diagram
With RSLogix™ 5000 Enterprise Series software, you need only one
software package for sequential, process, drive and motion control
programming. It includes language editors for relay ladder, function
block diagram, sequential function chart and structured text logic.
Example
Today many control systems, and most factories, assembly machines. Motion extensions allow
demand diverse control equipment. Typically this Structured Text Relay Ladder
LD programs to also manage servos for packaging Diagram
requires integration of different controllers, and robotic pick/place applications with the same
networks and software to make a system function. controller.
The Logix platform breaks this model by spanning
many control disciplines in a single, easy-to-use Function Block Diagram (FBD) graphically
environment, thereby reducing acquisition, training, depicts mathematical constructs as interconnected
development and maintenance costs. blocks. FBD includes extensions normally found in
dedicated process and drive controllers.
Coupled with industry-specific extensions, RSLogix
5000’s IEC61131-3 programming languages provide Sequential Function Chart (SFC) provides a
the means to simplify control systems. All graphical method for developing sequence of BENEFITS OVER CONVENTIONAL SOLUTION
languages are native to ControlLogix®, FlexLogix™, operation. SFC is useful for managing process
CompactLogix™, SoftLogix™5800 and PowerFlex® l One software package for multiple applications
batch and repetitive machine control. The SFC
700S with DriveLogix controllers. There’s only one
™ l One software package for small-to-large controllers
environment includes active step animation which
software package to learn – from large to small l Reduce training and maintenance cost
aids in machine-state diagnosis to reduce
controllers. When used appropriately, these l Reduce development time and cost
downtime.
languages will reduce overall program complexity,
improve the development process and reduce Structured Text (ST) is a Basic-like language ideal TECHNOLOGY
debug/maintenance costs. for specialized algorithms. This language, coupled
l Specialized industry-specific instruction set extensions
with Logix’s symbolic memory structure, provides
l All languages stored in CPU and are fully uploadable
The Relay Ladder Diagram (LD) graphically self-documented, easily-read programs.
l Highly integrated motion capabilities
emulates wiring of conventional relays. This ST supports the majority of LD and FBD instructions,
l Integrated process control
provides the foundation for sequential control giving the ability to control the full range of
l Superior diagnostics
applications such as material handling and applications.
1.4
Simplify programming with Reduce programming time as much as 40%
tag-based addressing and automatic
creation of structures
Our Logix controllers use a tag (or symbol) based addressing structure. Integrated Architecture Solution
Unlike conventional controllers, the CPU uses tag addresses internally With Logix control, the CPU understands real tag names, like ‘tank level’ and ‘flow rate’. There is no need
and doesn’t need to cross reference tag names to physical addresses. for the programming software to maintain a cross reference between tag names and physical addresses.
Data structures are also automatically created for network devices, I/O There is only one address – the tag name, so programs are much easier to read, even if you don’t have the
documentation. The user/programmer is not burdened with managing/designing memory addressing allocation.
modules and logic instructions.
In fact, the user never sees a memory address.
Example Tag names are shown in the program even if you
Conventional Solution don’t have the documentation.
Conventional PLCs use physical addresses for items of data. Each address usually depends on the type of
data item and the PLC’s addressing scheme. In addition, RSLogix 5000 PORT
MOD
NET A
NET B
automatically creates canned

PLC address Symbol
The programming software stores a table showing the “structures” for instruction, I/O
STS
N7:112 Tank1_Level
relationship between the physical address and the name X100 Inlet_Flowrate modules and network devices (Drives)
of the item to which it refers. M003 Tank1_Temperature on ControlNet and Ethernet. These 70
structures provide tags for status,

If the engineer doesn’t have a copy of the user program with parameters and diagnostics and eliminate the
documentation when connecting to a PLC, the addresses are need to create cross-reference documentation or
meaningless. This often happens in maintenance situations. having to use any manuals.
When accessing status, parameters and diagnostic information from network devices (i.e., Drives), I/O modules, BENEFITS OVER CONVENTIONAL SOLUTION
l
and even logic instructions (Timer status), conventional PLCs require the user to add additional logic to access
Greatly reduced engineering time and cost
l
specific bits or parse data. The user is required to reference a manual to know what bits/bytes to access or
Fewer programming and commissioning errors
l
parse within the “data blob” of the device, module or instruction.
Reduced downtime, easier maintenance – even if you don’t have the program
l Easier to understand documentation
Parameters/Data from a Drive (The “Data Blob”)
l Easier to understand structure of data when reading from controllers, HMI or interfacing to
business software
l Improve system uptime by providing a consistent structured access to instruction, I/O module and
network device diagnostics
TECHNOLOGY
l Logix CPUs use tag-based addressing
l Dedicated RSLogix 5000 programming software
1.5
Define tags once and FactoryTalk-Enabled Solution
reuse them throughout a With a FactoryTalk-enabled automation system, simply program tags and then reference them anywhere
in the system.
FactoryTalk-enabled system Program tags using

Logic Programming HMI Developer
A conventional control system requires creating and maintaining two

1 RSLogix, and then save
the project. With some
separate databases: one for the programmable logic controller and devices tags are created
another for the HMI application. With Rockwell Software® products automatically for you. 1 2
enabled by FactoryTalk Directory™, tags can be defined just once,
and then referenced and reused anywhere within a distributed system.
2 Use the tags created in
the controller program
FactoryTalk
Directory
Example directly in the HMI without
Conventional Solution creating an HMI tag database.
In a conventional automation system, programming PLC tags and then using them in an HMI software editor is
a complicated, multi-step process. That’s it. Tags are available for immediate use anywhere within the FactoryTalk-enabled system, even before
the program is downloaded to the controller. New tags are available immediately across the FactoryTalk-
enabled system. Tags are not held within a common database, nor are they duplicated in multiple databases.
1 Program PLC tags using a programmable logic control editor, such as RSLogix.
With Logix controllers, tags reside right within the hardware. With Allen-Bradley® PLC-5 ® and SLC 500™
devices, and with third-party controllers, tags reside within OPC (OLE for Process Control) Data Access servers.
Tags can reside on a single computer or on multiple computers connected to a network.
2 Export tags from RSLogix into a file, and then import the tag file into an HMI editor.
™

Duplicate any changes made l Reduces initial development time and ongoing maintenance costs
3 in the PLC editor in the HMI
software. Adding only a few
Logic Programming HMI Developer
l Eliminates importing and duplicating tag databases – and with devices such as Powerflex® drives
and 1756 I/O, you never even have to create a tag!
new tags to the PLC program 4 l Avoids a common database with a single point of failure
typically requires running a Two Databases l Supports tag databases distributed across multiple computers connected to a network
complete export/import batch
operation. TECHNOLOGY
PLC HMI l RSView® Enterprise Series software suite (RSView Supervisory Edition™,
As additional controllers and
4 other device tags are
imported into the HMI Manual
l
RSView Machine Edition™, RSView Studio™)
RSLogix & RSLinx®
l FactoryTalk Directory (used within Rockwell Software products)
software, continue managing import/export 3
1 l OPC (OLE for Process Control) Data Access v. 2.05-compliant servers
the export/import process and
2
synchronizing multiple tag
databases.
1.6
Reduce engineering time by doing Start-up in 80% of normal time using parallel development
electrical design and program

development concurrently
Conventional Solution Integrated Architecture Solution
Reduction in first time Additional saving in
Our RSLogix 5000 programming software allows you to separate physical System Layout design effort recurring engineering time
Design
I/O addresses from program tag names. This makes it possible to write
Electrical Device Electrical Device System Layout
PLC programs without knowing the physical I/O addresses. function and placement function and placement Design
Example
Electrical Design
Conventional Solution Integrated Architecture Solution
In traditional control system development, With Logix controllers, code can be written in I/O Addresses
Electrical Program
of all Devices
a system layout defines where all of the I/O devices parallel with the electrical design, using tags. At a Design Development
I/O Addresses
will reside and then an electrical design defines later date, the tags can be mapped to real I/O of all Devices
Program
which I/O points these devices will be wired to. points, with no requirement for re-writing the code. Development
Normally, you cannot begin program development This concurrent engineering approach helps to
until the I/O addresses are assigned, because you reduce the time it takes to engineer a system, Machine
Startup
need the addresses to write the code. because tasks that were once done in series
are now done simultaneously. Machine Startup

l Enables development of programs without a completed electrical design
l Reduces engineering time
l Create a library of reusable programs that can be used across multiple projects
TECHNOLOGY
l Tag aliasing separates I/O addresses and tag names
l Symbolic structured memory/data management
l RSLogix 5000 manages program/tag name associations automatically
1.7
Logix program structure reduces Integrator reduces program development by 90%
engineering and allows for

modular code
Our Logix controllers allow you to structure your application Controller Filter 1
The controller program structure allows the use of Tags Data
with multiple programs and routines. Each program has its own isolated multiple programs, each with its own isolated data
Routine For
Routine Filter 1
I/O
data area associated with it, to avoid conflicts with other programs. area. There is no requirement to manage conflicts
Filter 2
This makes it much easier to re-use code. in data table addresses between different Routine
Data
For
Routine Filter 2
programs. With Logix controllers, the steps for
Example
integrating code are much simpler: Washer 1
Consider a process with two filters and two 4) Create new tags and modify program to use Data
1) Copy filter program to filter 1 Routine For
washers. The washer and filter codes already exist new internal and I/O references Routine Washer 1
2) Copy filter program to filter 2
and need to be brought together in one application. 5) Review filter 2 code ton ensure references don’t Filter
Washer 2
3) Copy washer code to washer 1 Data
clash with filter 1 Washer Routine For
4) Copy washer code to washer 2
Conventional Solution 6) Review washer code to make sure data Logix5000
Routine Washer 2
5) Assign I/O addresses
The PLC program consists of a main program and references don’t clash with filter code
There is no need to re-assign internal addresses All the data associated with each program
subroutines. All the data for the program is stored in 7) Copy washer code to washer 1
used in each program, or check for clashes between is isolated within the program, making it
one data table. With this structure, the following 8) Create tags to support washer 1 and modify
the filter code and the washer code. much easier to use modular code.
steps must be followed: program to use new I/O references
1) Copy filter program to filter 1 9) Copy washer code to washer 2
2) Create tags to support filter 1 and modify program 10) Create tags and modify program to use new
to use new I/O references internal and I/O references
3) Copy filter program to filter 2 11) Review washer 2 code to ensure references BENEFITS OVER CONVENTIONAL SOLUTION
don’t clash with washer 1 l Program structure allows for modular code
l Each program has its own isolated data area
l No need to manage address conflict between programs
All PLC internal addresses need to be managed to avoid clashes. Library code needs very careful
l Program references to I/O are easily assigned - no need to search and replace throughout a program
management to organize data table.
l Easier to re-use libraries of code
Main Program
Library of code Potential data
Filter 1 Data table conflicts
Filter Table as the different
TECHNOLOGY
Filter 2 For all
programs
Washer 1 programs l IEC 61131 Task, program and routine model
Washer are brought
Washer 2 together l RSLogix 5000 simplifies tag data management
l Alias tags provide a layer of abstraction for I/O references
1.8
Streamline HMI development With RSView Enterprise Series, all of the software products in the suite are built on the same integrated,
scalable architecture. RSView Studio, a common development environment, supports developing both machine-
with a common editor level and supervisory-level HMI applications. Import entire machine-level applications into supervisory-level
applications, or drag individual components and drop them right into supervisory projects.
For example, while operators manage machine-level data from dedicated operator terminals and industrial
The RSView Enterprise Series software suite provides a common user computers on the plant floor, maintenance engineers can easily monitor the same machine-level data from their
experience that spans stand-alone machine-level applications up supervisory stations in remote locations—without having to recreate any graphic displays or tags. From an
RSView studio, an engineer can simply drag graphic displays from an RSView ME application, drop them into
through distributed supervisory-level HMI applications. Reuse machine-
a supervisory-level application and, with a minimum of effort, begin monitoring plant floor data.
level applications in large-scale distributed HMI systems – without
recreating graphic displays, tags, or other project elements.
Example
In a conventional environment, developing both machine-level and supervisory-level HMI applications
requires using completely different development tools, each with its own user interface, navigation tools,
graphical objects and learning curve. Sharing graphic displays, tags, and other project elements between the
two environments is difficult. Although graphics can often be imported, neither tags nor commands convert
cleanly, leaving much tedious work still to do. Typically, most customers find it easier to develop the two
types of applications separately—which often nearly doubles development time.

Machine-Level
l
HMI Developer
Supervisory-Level Reduces development time
HMI Developer
l Offers common development environment with consistent operator interface and navigation
features across multiple platforms
l Makes it easy to reuse machine-level applications within supervisory-level projects
TECHNOLOGY
l RSView Enterprise Series software suite (RSView Studio, RSView Machine
Edition, RSView Supervisory Edition)
l Allen-Bradley VersaView® CE and VersaView industrial computers
l Allen-Bradley PanelView™ Plus dedicated operator terminals
1.9
Collaborate on complex projects RSAutomation Desktop allows nearly any element of an automation system to be saved in a reusable
and reuse object libraries to build template – and every element in a project has a version number associated with it.
control systems quickly To work with a project element, a developer checks it out from a common database. When the project
element is checked back in, the system assigns a new version number and generates an audit message that
includes optional author comments, along with details about who made the change, what was changed, and
RSAutomation Desktop® manages complex industrial automation when it was changed. This audit trail makes it possible to analyze project changes across time and restore a
projects. A team can work together on a project concurrently without project back to any state.
fear of overwriting each other’s work. System elements can be created
once, stored as templates, and reused to quickly build or extend an As part of creating a new template, RSAutomation Desktop replaces the tags in each system element with
placeholders. When a template is dropped back into a project, RSAutomation Desktop automatically names
automation system and promote standards throughout the project.
it and updates all of the tags by replacing the placeholders with new tags, based on user-defined naming
Reusing objects and eliminating redundant tag entries and repetitive
rules, eliminating duplicate edits and efforts from multiple project team members.
testing can cut project development costs by as much as 40%.
Example
Managing multiple users and versions of an industrial automation project is too often a manual project
today, and engineers use a number of methods to duplicate and reuse parts of existing systems – but all of
the methods require significant effort and expense. With different versions of various project elements, and
with different people working on the same things, managing complex projects is difficult, time consuming
and error-prone. Using custom software is often tried, but this requires dedicated staff and is expensive to BENEFITS OVER CONVENTIONAL SOLUTION
maintain. l Dramatically reduces initial development time
l Eliminates the need to manually enter tags and object names for reused system components
l Allows for standards to be used consistently throughout an organization
l Makes messages about project changes available across an entire automation system
l Comprehensive audit trail makes it easy to track who made changes to project elements,
when and why
l Allows restoring any historical version of an industrial automation project
TECHNOLOGY
l RSAutomation Desktop
l FactoryTalk Audit™
l Leverages RSLogix and RSView products for logic and visualization editing
1.10
Cut programming time in half –
Save engineering time and cost reduce program overhead more than 25%
with Kinetix Integrated Motion
With Kinetix, the Logix controller handles both
The ControlLogix system handles both motion and sequential control in
sequential control and motion control. A single
a single platform. SERCOS communications to servo drives make them
software package is used and there is no need to
an extension of the Logix control system. This highly integrated solution write communications code between the motion
that we call Kinetix Integrated Motion reduces engineering and controller and the controller – it is the same
commissioning time. system. The solution is completed by
connecting the Kinetix servo drives via
Example the Logix SERCOS interface, making a
A packaging machine has sequential control and single, integrated system. The engineers
4 axes of motion control. Here’s how a conventional can now commission or program the
solution compares with the Kinetix Integrated entire system from a single point.
Motion solution. Tighter integration also simplifies
the collection of data, allowing
routine condition monitoring and Single software
package
preventive maintenance.
The conventional system has a PLC,
a motion controller and four servo BENEFITS OVER CONVENTIONAL SOLUTION
drives. There are typically three
l Greatly reduced engineering and commissioning time and cost
different pieces of software: one
l No communication code to write
for the PLC; one for the motion
l Single software package to program controller, motion functions and configure entire system
controller and one for the servo
including drives
drives. Each requires specific
l Only one software package to learn, install and keep up to date
expertise to operate, and
l Greatly simplified diagnostics and maintenance
probably a different serial cable.
l Reduction in space requirements, fewer terminations
l Scalable solution using only one hardware platform
PLC Servo controller Servo drive

Ladder Logic language tuning TECHNOLOGY
l Kinetix Integrated Motion
l SERCOS interface fiber optic communications
1.11
Extend the functionality As a distributed I/O network . . . There’s no easier or

smarter way to use remote I/O in your control system.
of your network Designed to be distributed close to the process, sensors and
actuators where the I/O density is low, modular I/O
assemblies and I/O blocks can be located remotely from the
Interconnecting your control devices with DeviceNet can provide a lot processor. DeviceNet is then used for communication. These
more than just an easier, less costly way to build a device network. products help speed setup of your network to lower system
DeviceNet’s features can help you to maximize performance and costs and reduce maintenance time.
productivity while saving time and money
Wiring up smart devices within a panel. . .Panel wiring
with DeviceNet provides installation savings for the media
Example
choices that are available versus conventional hard wiring.
Conventional Solution You save time during system startup, too, because the advanced diagnostics and configuration capability in
To automate your plant effectively, you need to network everything. Getting all your systems to speak the DeviceNet products is faster and simpler. You have the tools to verify control systems and be made aware of
same language, however, can be a problem. Even when a plant is “networked”, it may not be integrated for problems before they occur. If you need to replace a device, all components that conform to DeviceNet
the best productivity. And most of the time, you must hardwire all devices to a cabinet with terminal blocks standards are interchangeable, reducing downtime.
and loads of wiring running from the cabinet to each device, adding time and expense.
Automatic diagnosis analysis and troubleshooting information is available for DeviceNet networks. Many
DeviceNet plant-floor devices have built-in intelligence and communications capabilities to alert you to
problems before a failure occurs. Users can wire together a system including components such as drives
The DeviceNet network is a flexible and open, low-cost option you can use to connect industrial devices to a
intelligent motor starters, and sensors. They can then access the network remotely by modem, look at
network and eliminate costly and time-consuming hardwiring. Direct connectivity improves communication
diagnostics, configure drives, enable smart devices that predict what’s happening, indicate overload
and provides device-level diagnostics not available or easily accessible through hardwired I/O interfaces.
conditions – all benefits of the DeviceNet system.
Simple devices from multiple vendors that comply with DeviceNet standards are interchangeable, providing
flexibility and choices. Beyond providing a low cost, reliable device network, there are areas and functions BENEFITS OVER CONVENTIONAL SOLUTION
where a DeviceNet network is really good.
l Configure and monitor from one location
l Configure each device based on your needs
As a drives network . . . When your drives are networked
l Adjust parameters to tune network performance
together using DeviceNet, you can monitor and change parameters
l Debug and correct network and device issues easily
easily in networked drives. If you need to adjust parameters, you
l Use diagnostics to become aware of problems before production stops
do not need to connect directly to the drive. You can remotely
access all the information you need from a network.
TECHNOLOGY
You save time with remote configuration. With networked drives you can configure them remotely. Set up
l Widest variety of DeviceNet physical media to meet application needs
one drive, then replicate the configuration in similar drives. You can save large amounts of time and have
l All devices can communicate on a network or even across networks without translation or
faster startups because of this remote configuration capability.
special programming
l DeviceNet open network provides high interchangeability of components, excellent reliability
And when troubleshooting is necessary, you can easily look at the diagnostics built into each drive.
and consistent performance
DeviceNet can help awareness of potential problems – before they impact your production schedule.
INSTALL: Faster Start-Up – 2.1
2.1
SOMETHING: Something Here – 0.0
Reduce mounting and wiring costs by more than 70%
Minimize installation time with a (see Validation section 6.1 for details)
Kinetix Integrated Motion solution Integrated Architecture Solution

With ControlLogix, the automation controller and motion controller are in the same unit – there is no
Our Logix controllers handle both sequential and motion control and interconnection required. ControlLogix with SERCOS interface uses a single fiber optic cable to connect the
use SERCOS to connect to servo drives. This high-speed link saves servo drives. There is no separate motion controller to servo drive wiring. The motor, actuator and servo
installation time, increases reliability and improves performance. drive are automatically recognized by the control system and configured with a simple catalog number
selection. Additionally, use of the Kinetix 6000 power rail and LIM eliminate the need for individual
component wiring. Mounting and wiring time calculations are as follows:
Example
Layout and mounting : 75 minutes
A packaging machine has sequential control and four axes of motion control. Here’s how installation time of
Wiring controller plus 10 connections: 200 minutes
a conventional solution compares with the Kinetix Integrated Motion solution. - all pre-made screw-in connectors:
Wiring power components:
Conventional Solution - 1 device, 4 power and 1 pre-made connection: 40 minutes
Testing: 20 minutes
The conventional system has a PLC, a motion controller, four servo drives and associated power components
including contactors, fuses, circuit breakers, filters and terminal blocks. The servo drives are hard-wired to Total time: 335 minutes (5.6 hours)
the motion controller, typically using 20 wires (40 wiring points) for each axis. The servo controller is also Labor cost: $50/hour
wired to the PLC, typically requiring another 20 wiring points. Conventional motion controllers often require Total time cost $280
complex networking setup, addressing, etc. The following are mounting, wiring and testing time
calculations, based on actual tests showing that it takes about three minutes per point: BENEFITS OVER CONVENTIONAL SOLUTION TECHNOLOGY
Layout and mounting: 230 minutes l Greatly reduced installation time and cost l Kinetix Integrated Motion
PLC to motion controller wiring: 10 wires, 20 points = 60 minutes l Increased reliability l Kinetix 6000 Multi-Axis
Motion controller to servo drives wiring: 4 axes, 80 wires, 160 points = 480 minutes l Increased noise immunity Servo Drive
Power components wiring: 8 devices, 50 wires, 100 points = 300 minutes l Control architecture flexibility – multi-axis systems are l Line Interface Module
Testing: 70 minutes easily configured without complex wiring or network setup
Total time: 1140 minutes (19 hours) l One optional Line Interface Module (LIM) can replace nine
Labor cost: $50/hour individual components, eliminating up to 98 interconnecting
Total time cost: $950 wire terminations — can be used with a variety of servo
and AC drives
Save Panel Space
Fiber optic connector

INSTALL: Faster Start-Up – 2.2
2.2
Upgrading motor control systems To speed and simplify startup, motor starters are mounted in a centralized MCC. MCC starter units plug into
the power distribution backplane of the MCC. Plug-in starters can be moved or replaced without reworking
supply wiring or conduit.
For monitoring, the motor starter is equipped with an

intelligent E3 Overload Relay. This relay provides the
The hardwired arrangement of a motor control system can limit the same protection as solder-type overload relays and
amount of process information available and its inflexibility makes enhances that protection with:
changes difficult and expensive. The combination of intelligent motor l current monitoring (phase/ground fault/imbalance)
l inputs to monitor local contacts
controls, industrial networking and motor control centers (MCCs)
l remote controlled outputs to operate the starter
provides a motor control system that is flexible, easier to install and
l warnings of impending overloads or faults
start up, and provides the high level of control and monitoring demanded
l built-in DeviceNet communication
by today’s competitive environment.
The DeviceNet network transmits the enhanced process
Example information, including auxiliary contact status, via a single
network cable. This cable is routed to multiple starters and
is connected to the scanner. The IntelliCENTER® MCC, with
The motor starter enclosure is permanently mounted and connected with conduit to the motor and the power
built-in DeviceNet media, combines the advantages of
source. Wires that are sized to handle the motor load are installed in these conduits.
intelligent devices, networking and an MCC
For monitoring, auxiliary contacts are installed on parts of BENEFITS OVER CONVENTIONAL SOLUTION
the motor starter such as the contactor, overload relay and
l Data from intelligent devices permits higher level of process control
other local devices. Each contact requires a separate
l Condition warnings allow proactive response to potential downtime situations
control wire that is routed to an I/O module. Often, the
l Faster installation – only one main power connection is required
control wires are routed in a separate conduit. This
l Built-in, pre-configured and tested network reduces installation and startup time
method of monitoring requires a substantial investment
l Changing or expanding motor control needs easily accommodated
in wire, conduit, I/O modules and labor.
l Easier device configuration – intuitive software is suitable for use by maintenance electricians
l Reduced arc-flash exposure by monitoring motors over network without opening enclosure
Starting up this “hard wired” system is time-consuming.
Every wire must be properly installed, marked and verified
against the PLC program. A miswired connection may
TECHNOLOGY
require hours of troubleshooting to find and correct.
Adding control wires for additional status monitoring is l Intelligent electronic overload relays (E1 Plus and E3)
extremely difficult. If the motor is replaced with a larger l PowerFlex variable frequency drives
motor then the starter, wiring and conduit may all have l SMC™ and SMC Flex soft starters
to be replaced. l IntelliCENTER MCC with built-in DeviceNet and intuitive software
l RSLinx software
OPERATE: Improve Performance – 3.1
3.1
Improve decision making with Each RSBizWare software module can be applied independently to solve a specific business issue,
access to real-time operating minimizing up-front costs and providing a quick return on each investment. For example, choose modules
depending on immediate business needs to manage order flow, improve uptime, analyze operational data,
information manage capacity, predict the impact of changes, and integrate information between control systems and
business applications. Unlike a traditional solution, each RSBizWare module also works together with others
as an integrated suite, sharing data via an underlying FactoryTalk architecture. Because data entered once
In a traditional manufacturing environment, a variety of software tools can be immediately reused by any module in the suite, time and cost savings grow incrementally as
are used to improve different areas of an automation system. Each tool additional RSBizWare modules are implemented into the system. And because the modules are integrated,
serves only a single, specific purpose and provides only a limited view the addition of each new module deepens and broadens the overall view into the entire enterprise -- and
into just one facet of the system. Using information-enabled architecture no custom code is required!
from Rockwell Automation can optimize your automation systems and

FactoryTalk Common Factory Model
provide a complete up-to-the-minute view of the entire enterprise.
Analyze Plant Order Flow Plant Capacity Plant Data
Operational Efficiency Management Simulation Management Management
Data RSBizWare & Scheduling Arena RSSQL
Arena
RSBizWare PlantMetrics RSBizWare RSBizWare
Historian Scheduler
Example Scheduler
RSBizWare RSBizWare
PlantMetrics MaterialTrack
A traditional solution requires configuring and maintaining a number of different optimization software tools,
including a data historian, downtime tracking system,a scheduling system integrated with an ERP (enterprise
resource planning) system, simulation software, and a data transaction manager. Integrating and maintaining
these various software tools typically requires significant manual rework,
repetitive data entry, and expensive investment in custom code. RUN RUN
Order Flow
Management Plant
& Scheduling Simulation
Plant Capacity
Efficiency Management
Analyze BENEFITS OVER CONVENTIONAL SOLUTION

Operational
l
Plant Data
Data Management Reuse manufacturing data across multiple software modules to analyze and improve
manufacturing processes
l Achieve an integrated view into an entire enterprise without expensive custom code
or duplicated data entry
RUN RUN
TECHNOLOGY
l RSBizWare suite of software products
l FactoryTalk Data Model (used within the RSBizWare products)
l Tag-based architecture
3.2
Simplify information access by using EtherNet/IP Solution

an EtherNet/IP® network With a single EtherNet/IP network linking the factory floor to the control room and business
systems, all information and control systems can operate simultaneously and reliably. Because
EtherNet/IP is Ethernet 802.3 compliant, it allows control information and commercial
technologies such as voice-over-IP (VoIP) to co-exist on the same network — to provide better
manageability, easier maintenance and faster trouble-
Use a single EtherNet/IP network to link management information
shooting. As part of the NetLinx
networks and plant floor control networks in your manufacturing architecture, EtherNet/IP can
enterprise also incorporate existing
NetLinx networks as well as
other networks such as
Example FOUNDATION Fieldbus or
Data Highway Plus.
In a typical plant scenario, several network communication systems are used to link the factory
floor to the control or computer rooms. In the example shown below — phone, video and control
are used simultaneously yet have been networked separately to provide the timely and reliable
information that’s needed to manage plant operations and productivity. And each network
requires its own operator training, maintenance and control specialists.
The actual user implementation may

vary from this conceptual architecture.

l Fewer (and less complex) networks to manage
l Leverage existing knowledge base for training and maintenance
l Wider bandwidth handles large amount of information
l Allows less network without lessening any performance
l EtherNet/IP is standard Ethernet, allowing it to take advantage of commercial off-the-shelf
products and technology
TECHNOLOGY
l Proven and reliable network – in commercial use since the1970’s, industrial use since 1990
l Leverages existing commercial technologies for industrial use
l Can easily be used with NetLinx architecture from Rockwell Automation
3.3
Define graphic displays once Integrated Architecture Solution
and reference them throughout With RSView Supervisory Edition, displays do not need to be copied into multiple HMI stations. Instead,
any graphic display can be referenced from any other display, on any HMI station, within a networked
a distributed system system.
From any graphic display, browse any computer in the system, select another
With the RSView Supervisory Edition software, design graphic 1 graphic display, and create a reference link to it.
displays once and reference them at design time and at runtime from any
To make updates to a
client station on a network—without copying, importing, converting,
or re-entering tags or commands. Because graphic displays are 2 running system, simply
open and edit the original
Eng. Station Client
RSView SE
Server
RSView SE
Server
RSView SE
Server
referenced, not duplicated, edits update automatically across the system.

graphic display, and then One Display
save the changes. for the Entire System
Example
The changes take effect
Conventional Solution the next time the display is
A traditional HMI typically includes multiple stations, with each station hosting its own HMI project. accessed on any computer in
It is often convenient to use some of the same graphic displays across multiple projects. The more the system.
projects in which a graphic display is copied, however, the greater the maintenance burden to keep all
of the duplicated displays identical. Copying a graphic display into multiple HMI stations typically
RSView SE Client RSView SE Client RSView SE Client
requires multiple steps:
Export the graphic display to a file.

1 BENEFITS OVER CONVENTIONAL SOLUTION
l Significantly reduces development time and ongoing maintenance costs
Import the graphic display into one or more HMI projects on multiple stations.
2 l
l
Eliminates importing and duplicating graphic displays
Supports projects distributed across multiple servers on multiple computers
HMI Client HMI Client HMI Client connected to a network
In each project where the graphic display
3 now resides, manually fix tag mismatches,
correct conversion errors, and test thoroughly.
COPY COPY COPY
l Makes it easy to update graphic displays across an operating
automation system
To edit the graphic display, either

4 repeat the same changes manually
for each duplicated display in Eng. Station Client
TECHNOLOGY
l RSView Supervisory Edition
l
HMI Server
FactoryTalk Directory (used within Rockwell Software products)
each project, or take the
system offline and repeat the
export/import process and
manually re-enter tags and commands.
3.4
Match your control network to Reduce programming 30% by using NetLinx networks
today’s needs; provide simple future

expansion without risk You can select components and media according to your specific application with choices like EtherNet/IP
for information and control, ControlNet for deterministic control, and DeviceNet at the device level (also in
conjunction with FOUNDATION
Effective automation relies on networking even the simplest devices fieldbus for process With NetLinx, only one network is needed to collect,
control & configure
and then being able to communicate with everything on the network – applications). All networks
everywhere! With so many devices, networks and protocols, it is use the open international
difficult to get all the systems to interoperate and even more difficult Common Industrial Protocol All devices can be connected to a single network
(CIP) standard and share a
to maintain. NetLinx provides a risk-free solution to the problem.
universal set of communication
Example services that enable you to
move data across multiple I/O Controller
Conventional Solution Drive
networks effortlessly.
For effective plant automation, hundreds of devices must be networked. Most plants already have a number If a second network is
needed, it can be added
of networks installed for different purposes – but with the wide range of devices, networks and protocols, Each network has its own without any additional
it’s difficult to get all systems to share data. The additional programming takes time and requires complex inherent features and benefits programming
integration – requiring significant that allow the user
Traditionally, separate networks or conections have been used
startup/ troubleshooting, consuming to collect data, control devices or configure those devices unprecedented levels of flexibility. Choose to implement one network, combine two, or design a system
valuable computing resources depending on your application and complexity. Without special programming, you can design a control
A PC was used to
and impeding the ability individually configure system that completely fits your unique control needs today and have available no-risk expansion for
to react to change quickly. each device.
tomorrow.
Additional program
code was needed to
check data. BENEFITS OVER CONVENTIONAL SOLUTION
l Control devices with faster throughput, greater determinism and repeatable performance across
multiple platforms
l
PLC
Configure all devices from a simple sensor to a complex controller
I/O I/O
Drive l Collect data from all of the devices on the networks, anytime
l Peer-to-peer interlocking
Network solutions from Rockwell Automation form a seamless, integrated open architecture called NetLinx.
TECHNOLOGY
It’s the best architecture for complete bridging and routing of control information and data. NetLinx
integrates all the components in an automation system and doesn’t require any programming to integrate l All networks use open international CIP standard
multiple networks – reducing installation time and costs, simplifying maintenance and expandability . . . l Seamless communication from highest-level business system to smallest device
lowering your overall risk. l Multi-vendor interoperability
3.5
Assure virtually non-stop monitoring Integrated Architecture Solution

A Rockwell Automation FactoryTalk-enabled system does not require any custom coding for redundancy.
with built-in failure detection and RSView Supervisory Edition HMI servers, RSLinx and other OPC Data Access 2.0 servers, and FactoryTalk
Directory servers can all be quickly and easily configured to run on both primary and secondary computers.
recovery Once configured, each redundant pair of servers is available to all FactoryTalk-enabled clients within the
system. Adding additional clients does not
When the connection to a primary computer running in a distributed require any additional configuration. During
automation system fails, what happens to the rest of the system? runtime, if the connection to a primary
“Wow, the primary server
computer fails, FactoryTalk automatically
In a traditional scenario, the entire system may suddenly become was down for 15 minutes. Looks like
this redundant system saved me
switches all clients to a backup computer
unresponsive and inoperable. In a FactoryTalk-enabled system, $150K, just today.”
within 30 seconds, and can automatically
operators may barely notice the switch to a backup computer. switch them back to the primary computer
Underlying FactoryTalk services quickly detect server failures, when the connection is restored—all without
seamlessly failover to backup computers, and reconnect to recovered any custom programming, client configuration,
or operator intervention.
Example
In a traditional automation system, engineers
spend considerable time and effort writing l Ensures a high level of system availability, with automatic failure detection and synchronized failovers
custom code for each different software l Enables system-wide redundancy options, with no custom programming required
“Uh-oh, the server’s
product to allow it to handle server failures
down again! $10K every minute.... l Eliminates “out-of-sync” conditions where some client components failover to backup computers
$20K, $30K, $40K.......we can’t
and switchovers between primary and backup afford this.” at different times
computers. During runtime, the custom code l Provides a consistent way to configure redundant host computers; allows setting up redundancy
on each host computer detects failures and options only once for each server pair
notifies its associated client components. Each l Makes redundant server pairs available to all FactoryTalk-enabled clients in a system, without
client component then independently fails over requiring any client configuration
to a backup computer. Because different
pieces of custom code use different algorithms
TECHNOLOGY
to determine failures, some client components may failover to a server on a backup computer while others
l RSView Supervisory Edition
do not. As a result, client workstations may end up using more than one computer as the active server,
l RSLinx
which can scramble data and halt system operations.
l FactoryTalk Live Data™ (used within Rockwell Software products)
l FactoryTalk Directory (used within Rockwell Software products)
l OPC (OLE for Process Control) v. 2.0-compliant data servers
3.6
Reduce downtime with diagnostics Reduce downtime with diagnostics
Motion control is often used in critical high-speed machines in

production operations. Using Integrated Architecture, you can easily 3 The ControlLogix system constantly monitors
critical parameters within the servo drive and
can alert the operators to a potential problem
monitor the health of your control system and be alerted to potential
before the system stops. The alarm message
problems before they cause production to stop.
can easily be sent to any part of the
Example control system - supervisory PC,
tower lights, or even a pager.
1 A filling machine uses a motion controller to

synchronize the filling nozzles with continuously
moving bottles. The servo motor drives a ball screw
2 During prolonged operation, the ballscrew
becomes contaminated with splashes and the
load on the servo motor starts to increase.
that positions the filling nozzles.

l Fewer unplanned shutdowns
l Excellent information availability allows easy fault tracing & correction
l Lost production minimized
l Reduced risk of damage to motor and other plant
TECHNOLOGY
l Kinetix Integrated Motion
l SERCOS fiber optic communications
3.7
Improve plant reliability through The XM Solution

XM modules may be applied as a stand-alone system or they can be integrated with the control system
integrated condition monitoring using the existing network. The distributed and modular DIN-rail mounted XM architecture allows for
optimum design and placement of the modules near the machinery being monitored. This advantage
reduces the costs of installing an on-line condition monitoring system when compared to traditional
rack-mounted systems.
Our XM® series of intelligent, specialty I/O modules can process in real-
time the critical parameters used in assessing the current health, and
predicting the future health of industrial machinery — providing
EtherNet/IP
machinery protection where needed, and reducing downtime.
Example
Conventional Solution ControlNet
Traditional condition monitoring and protection systems have required a separate rack-mounted system with EtherNet/IP
Other
limited integration to the control system. The condition monitoring equipment is often placed far from the Networks
actual machinery being monitored, requiring long field wiring runs to a centralized location. This can result
in installation costs that are two to three times as much as the monitoring system itself. These solutions DeviceNet
offer limited integration to other systems within the facility. The results have been expensive, centralized
and proprietary islands of information. Analog Analog
Sensors Sensors
EtherNet/IP
4-20mA Outputs
ControlNet BENEFITS OVER CONVENTIONAL SOLUTION

Modbus
l Combined condition monitoring and protection system in one

l Leverage existing IT network infrastructure (XM is DeviceNet based)
l Modular and scalable design allow for cost-effective low-channel count installations
l Lowest total cost of ownership
Analog Sensors
TECHNOLOGY
l DIN-rail mounted
l Real-time data acquisition
l Standard DeviceNet connectivity
l Optional Ethernet with gateway module
l Digital configuration with included serial utility
3.8
Extending your Process applications can be programmed in function block language and integrated with operator interface
systems. Redundancy, batch and other functionalities are all available. Moreover, users can reduce training
process control system and equipment stocking costs, reduce downtime and maintenance costs and improve production by using
common architecture and equipment across the entire plant.
Today’s industries use a wide range of application types to produce their

Control systems must share information and ultimately produce usable documentation. In order to provide
goods. Traditionally, each of these varied application types has required plant-wide integration, control and information systems must establish a common language and machine-
a specific type of automation system to control it. state models throughout the plant, ensuring consistent operations protocols (e.g., giving process and
discrete HMI screens a common look and feel), and complying with standards. Rockwell Automation’s
Integrated Architecture from Rockwell Automation uses the abundant Integrated Architecture provides this functionality. The requirements of the entire range of control disciplines
processing power of Logix controllers, along with network and used in most production facilities now can be fulfilled using one common architecture with common
controllers, common communication services, common operator interface systems and common information
visualization technologies to provide a true multidiscipline controller
systems.
for sequential, process, motion, safety and drive control applications.
Users can now take advantage of multiple language support (ladder,
function block, sequential function chart and/or structured text) to
program in the language best suited for the application.
Example
Traditionally, process operations such as batch management are controlled by a highly inflexible distributed
control systems (DCS) which could only be programmed using fixed function blocks or a limited flow chart
language. Discrete applications such as packaging and material handling have been controlled by high-speed
Programmable Logic Controllers (PLC) in ladder logic. Other applications such as information, motion BENEFITS OVER CONVENTIONAL SOLUTION
l
and drive control have required their own unique control solutions, programmed separately in their
Reduces development time
l
own languages.
Reduces maintenance and downtime costs
l Reduces storeroom costs
l
Users of these separate control systems face a range of challenges and costs including the integration of
Plant-wide control with a single controller platform – and a single programming package
l
plant automation activities and sharing of information at both the control and management levels.
Easily conforms to S88 Batch Control standard using Phase Manager software
DCS users who also require other types of control systems can have difficulty meeting new requirements
for product genealogy tracing due to difficulties in information-sharing between systems. TECHNOLOGY
l Process-specific control instruction set
Integrated Architecture Solution l Available Function Block, Sequential Function Chart, Ladder Logic and Structured Text languages
Rockwell Automation’s Integrated Architecture provides users with a single control infrastructure for the l Redundancy
entire range of automation applications, including process. No longer must users work with a multitude of l FOUNDATION fieldbus and HART connectivity
different controller types, software types, language types and communications issues.
3.9
Extend system visibility through

plant-wide messaging Integrated Architecture Solution
Real-time data in Rockwell Automation’s machine and supervisory level HMI systems can be quickly
Integrated Architecture from Rockwell Automation delivers the Right extended to message display systems using the RSView Studio common development environment.
Information to the Right Place at the Right Time, maximizing your Driving factory-wide messaging directly from the HMI system
minimizes custom code in a controller that would
production efficiencies.
otherwise impact scan time and system
performance. By delivering the right
Example
information to the right people,
Conventional Solution real-time decisions can be
A traditional automation system makes critical real-time data available only at the machine and supervisory made without consuming
HMI levels. Many applications exclusively use hard copy or handwritten production data to address quality valuable maintenance and
and performance issues. Conventional message display applications require increased ladder programming engineering resources. Creating
and separate, dedicated point-to-point connections to convey critical messages on the factory floor. This visibility within production metrics,
results in increased response time, leading to higher installation and maintenance costs due to the need for machine alarms, and quality indicators
disparate messaging systems. The only alternative is requesting non-real-time performance data from plant drives accountability and produces results:
supervisors, wasting precious time and resources. • Increase access to production data
• Optimize manufacturing and monitor efficiencies
• Improve response time through instant plant-wide communications
• Reduce production costs with enhanced machine level controls

l Increase reliability by improving response time to critical conditions
l Improve manufacturing efficiency and drive accountability in production and maintenance
l Extend factory-wide messaging beyond machine and supervisory control
TECHNOLOGY
l RSView Enterprise Series (RSView Studio, RSView Machine Edition, RSView Supervisory Edition)
with InView control object
l Allen-Bradley InView™ message display products
l Allen-Bradley PanelView Plus operator interface terminals
l Allen-Bradley VersaView and VersaView CE industrial computers
l NetLinx architecture allows seamless communications throughout your control system
MAINTAIN: Use Superior Diagnostics – 4.1
4.1
Easy data access to diagnose

and troubleshoot devices To check parameters in a complex
throughout a facility device like a drive, the control
engineer can adjust parameters from
Navigate to
troubleshooting
information
a central computer connected on

Integrated Architecture makes it extremely easy to collect and analyze Generate a hard copy of
diagnostic & troubleshooting
EtherNet/IP. There is no need to
data from anywhere in your facility. Data is exchanged seamlessly over information
connect to each drive separately.
multiple networks. Diagnosis and analyzing functions to be performed Navigate to
device properties
remotely from centralized locations. And it can get even easier. Enabled
by FactoryTalk diagnostics, monitoring Navigate to any fault
on the network
Example systems can generate diagnostic
Conventional Solution messages and route them to a
central database, where they are available for tracking
Data is only available on the local network. To get data to
and analysis. RSNetWorxMD software scans networks
remote or centralized locations involves lots of
and devices, identifies and analyzes potential problem areas, displays readable messages with health
programming or manually collecting data that has been
indicators for each device, and offers steps for solving problems. The software provides an easy-to-read
logged to numerous clipboards. An engineer who
assessment of the health of the entire network.
wants to understand why one line appears to be
working more efficiently than another has to manually
identify relevant parameters, map parameters to
operating conditions, and then consult each manufacturer’s
documentation to resolve their diagnosis. Supervisors analyze
data from each device on each network separately – there is no way to BENEFITS OVER CONVENTIONAL SOLUTION
monitor the overall health of the entire network.
l Easy access to data for analyzing problems
l Easy access can be gained to parameters in controllers and devices like ac drives, electronic
overloads, etc.
To analyze variables and troubleshoot l No need to write code to transfer data around the system – NetLinx architecture does this
production problems remotely, engineers automatically and seamlessly
can use a computer with RSLinx software
connected to EtherNet/IP, browse to the
data that they want and copy it to a TECHNOLOGY
clipboard. The Integrated Architecture will l NetLinx architecture allows you to connect to any device on your control system from a single point
even allow you to browse to data that is l Information is seamlessly routed from devices and through controllers as required
connected on sub-networks without a l RSLinx has OPC/DDE communications capability for transferring data
direct connection. The data is pasted into l RSNetWorx™ MD for DeviceNet, ControlNet, EtherNet/IP
a spreadsheet, allowing the engineer to l FactoryTalk Diagnostics
analyze the data without being on-site.
4.2
Decrease defective module replacement time
Use Auto Device Replacement by at least 30 minutes
to Reduce Repair time
Intelligent devices like drives and motor starters need to be set up
correctly in order to operate. With Auto Device Replacement (ADR)
technology, available only from Rockwell Automation, dramatically
1 A brand new unit is sourced straight from
stores, to replace the damaged unit.
reduce lengthy set-up time involved when replacing damaged

equipment.
Conventional Method
1 Put the device on as an unused node on

the network.
2 Set the device address.
2 The DeviceNet scanner automatically

sets theicorrect node address and
downloads the original device parameter
configuration. The device is back on line
with a minimum of downtime.

l Virtually eliminates setup time
l Minimize required maintenance staff time
l Minimize unplanned downtime and subsequent lost production
l Eliminate need for computer with configuration software to replace a failed device
TECHNOLOGY
3 iDownload the configuration from another
iicomputer on the network (assuming it is l DeviceNet makes it easy to locate and identify problems
stored) or manually enter the configuration on the l DeviceNet scanners store configuration parameters
front panel. This will take a while and it assumes l Intelligent motor control, drives, soft starts and electronic overloads all support ADR Functionality
the configuration is backed up on the network. l Distributed I/O adapters easily add system connectivity
4.3
Audit and manage changes to Integrated Architecture Solution

In a FactoryTalk-enabled automation system, Rockwell Software products throughout an enterprise monitor
FactoryTalk-enabled systems system changes, generate detailed audit messages, and then route those messages to a central database,
where they are available for tracking and analysis. During the normal course of operations, FactoryTalk-
enabled products, such as RSLogix, generate audit messages when users log into the system, change data
Who did what? When? Where? Why? The answers to these questions configurations, or change I/O configurations. Other areas of the system generate audit messages when
are critical when changes to an automation system cause unforeseen recipes, logic programs, or batches are downloaded or configured, and when other normal operation
activities cause changes to the system. All of these messages are routed from all participating products
side effects, and often necessary to maintain regulatory compliance. In a
to a central audit log for storage and analysis.
FactoryTalk-enabled system, Rockwell Software products share an audit
capability, which makes it easy to maintain a comprehensive, central When a system change causes unintended side effects, supervisory staff can use RSMACC™
record of all changes made throughout the manufacturing system. (Maintenance Automation Control Center) software to quickly pinpoint what happened and where it
happened. Maintenance staff can restore an earlier, unchanged version of the ladder logic program and
get the plant running again. Meanwhile, supervisory staff can analyze why the change caused problems
Example and suggest alternatives.
In a traditional automation system, each software product typically has its own change tracking system
associated with a separate database. For example, changes to PLC logic are tracked in one system
while changes to an HMI are logged in a completely different system. Suppose a maintenance
technician makes a change to a ladder logic program to solve a problem on a packaging line. The
change triggers problems in two other areas of the system several hours later. Engineers scramble to
uncover which change in which program caused the failure—while the system remains disabled,
at considerable cost to the company.

l Consolidates system-wide changes into a central database
l Makes it easier to maintain compliance with U.S. government regulations, such as 21 CFR Part 11
l Makes it faster to identify and resolve unexpected problems throughout the system
TECHNOLOGY
l RSMACC (Maintenance Automation Control Center)
l FactoryTalk Audit (used within Rockwell Software products)
4.4
Reduce troubleshooting costs by
Remote diagnostics using several hundred dollars per call
Web-based communications Specific reports can be graphically tailored to present information in a manner that suits different levels of
inquirers –- production information for manufacturing management, performance data for engineering, or
shift costs to compare against budgets or other financial needs.
Integrated Architecture communications capability makes remote
diagnostics very easy and powerful. You can remotely connect to a
The Enhanced Web module also may be used to notify users of critical events or report status (such as a
EtherNet/IP network to monitor the system and apply a web-based machine about to break down) via e-mail or a paging system. The problem can be rectified remotely,
solution using a standard web browser. minimizing downtime or lost production.
Example
To remotely access any control system, specific tools and equipment are necessary. A computer can be used
to “dial in” to a modem via phone line. And once successful access is made, connection is made only to the
specific control system processor connected to the access modem. If adjustment or tuning of system
components beyond the processor is needed, they cannot be completed through the remote access
connection. The person making the inquiry is severely restricted unless they have some specific knowledge
of the control program in the processor. A problem situation can be improved, but considerable time and
production may be lost.

Remote access using Web-based communications can be much simpler and faster. If the system with
EtherNet/IP is connected to the Internet or to a dial-up router, the entire network can be remotely accessible
using the Web technology, not just the processor. This remote monitoring is not limited to just controller
l Expanded reach of information, monitor information from anywhere
programs; you can also access motion control systems and networked devices like drives and intelligent
l Only a standard web browser is needed
overloads.
l Information can be tailored to fit the needs of different levels of people (diff levels of
When a web server such as the Enhanced Web module is incorporated into the control system’s EtherNet/IP project/application management/responsibility
network, users can view this control information from a standard Web browser such as Microsoft Internet
®
Explorer. Anyone concerned about the line’s current status can access current system information remotely
real time over the Web. This allows plant mangers, engineers or maintenance specialists to monitor control TECHNOLOGY
system data at their convenience without needing any specific programming software or communications l Communication architecture allows connection via modems
software. l Integrated Architecture allows you to “drill down” to any device in your system
l All Allen-Bradley EtherNet/IP devices have Web servers built in
l With proper software, you can adjust or change device parameters remotely
SUPPORT SERVICES: Maximize Production – 5.1
5.1
What’s your maintenance strategy? Eliminate

Unplanned
Service Assessments
Baseline Evaluations of Plant Floor Technical Skills, Procedures and Equipment
Downtime
Events Integrated Condition Monitoring
Highly efficient processes, cutting-edge technologies and continuous Predictive Maintenance Products & Services for Rotating Equipment
pressure on the bottom line have changed how companies approach Rockwell Automation Asset Management Portfolio
machine and plant floor maintenance. Consistently OnSite MRO Process Management
Produce to
Specifications Remote Monitoring Services
Example System Monitoring/Diagnostics by Offsite Automation Specialists
Conventional Solution Industrial Network and Security Services

Stabilize Security Assessment, Network Validation, Evaluation and Maintenance
Industry has become accustomed to a “run-to-fail” or reactive approach in dealing with maintenance Maintenance
issues such as: Budget Parts Management Agreements
Rockwell Automation Owned On-site Spare Parts Inventory
• Eliminating unplanned downtime events
• Keeping equipment running to specifications OnSite Support Services
• Stabilizing the maintenance budget Reduce Troubleshooting, Repair and Maintenance of Automation and Related Equipment
Downtime
• Reducing planned downtime duration Duration Training
• Decreasing time needed to implement change Instructor-led Training, Self-paced Training and Certification Programs
Maintenance remains one of the few business areas where even a modest improvement can provide Repair Services
a significant boost to the top and bottom line, as well as product quality. Improve Remanufacturing, Repair, and Exchange Services and Renewal Parts
Speed
to change Phone Support
Strategic Maintenance Solution TechConnect™, TeamSupport and Technical Application Services
As the role of plant floor maintenance becomes increasingly important to overall company performance,
an a la carte approach to maintenance activities is often no longer suitable to produce the desired results.
Instead, it is now necessary for companies to take a strategic approach to maintenance, one that:
• Includes a comprehensive plan that identifies needs and objectives and coordinates every BENEFITS OVER CONVENTIONAL SOLUTION
organizational function to reach those objectives
l Reduces equipment failure and extends component life
• Stabilizes the maintenance budget and overall production costs
l Works well for capital-intensive and production processes
• Begins in the engineering department during system design
l Spend less time and money on maintenance
• Leverages an integrated contol system architecture
l Proper resources are in place and available when needed
• Maximizes asset performance and uptime by applying the right
l Maximizes return on the automation investment
reactive, preventive and/or predictive maintenance methods
TECHNOLOGY
l XM intelligent I/O modules designed for machinery protection and condition monitoring
l Remote Access Dial-in Kits connect to a remote site’s network and/or controller to perform
remote maintenance
l The 9300-RADES Modem allows remote connection to an EtherNet/IP network for system
component monitoring using only a network browser
VALIDATION: Real-World Examples – 6.1
6.1
Validating the economic DESIGN

Save engineering time, reduce learning time
benefits provided by the when designing your control system
Integrated Architecture SECTION 1.3

Using the right language reduces program complexity,
Validating how much time and how many dollars can be saved using Rockwell Automation’s Integrated improves development, reduces costs
Architecture is a challenging task. Improved development times vary from customer to customer because the According to one system integrator, “The ability to implement the right code in the right language shaved 10
amount of reduction is application-specific. Installation costs vary for several reasons including local labor to 20% of development and startup. Additional savings came from the ability to use the SFC language to
rates, codes, and the scope of the job. Reductions in downtime costs vary because these costs are directly document the process during the bid/design phase and use these charts directly, rather than starting over in
related to the product being processed or manufactured. The ability to monitor a production system from any another tool.”
place in a plant may be extremely valuable in a large facility with limited operating engineers, and less
SECTION 1.4
valuable in smaller facilities or where each process has an attendant operator. Reduce programming time as much as 25%
Several system integrators referenced jobs where tag-based addressing had saved them time, and thereby
In the following pages, internal and external system integrators and Rockwell Automation customers
reduced programming costs. Where code is reusable, system integrators report reductions in programming
describe several application areas where they’ve been able to reduce development time and installation time as high as 40%. System integrators attribute these reductions to the fact that Logix-based systems
costs, produce more product per shift, and troubleshoot and maintain their manufacturing processes more allow programmers to reuse tag structures, reducing the time normally associated with planning one or more
easily using Rockwell Automation’s Integrated Architecture. data tables. The ability to configure instead of programming alarm functions further reduces programming
time.
Although your results may vary, the comments, estimates, and results are intended to help you identify
SECTION 1.6
several areas where Rockwell Automation Integrated Architecture products may help reduce your
Start-up in 80% of normal time using parallel development
development, installation, operating, and maintenance costs.
An experienced PLC integrator estimated that a 2000-tag system, programmed using traditional methods and
control platforms, could take as long as 12-16 weeks from inception to start-up. Concurrent engineering
could effectively pull the scheduled startup date of the same job within 10-12 weeks from the initial start
date, a reduction in the system development schedule of approximately 20%. And if the decision was made
at some point during development to change from one I/O type to another (Example: Rack-based I/O to
FLEX I/O), it would require a minimal amount of time to modify the tag configuration program instead of
a time-consuming program re-write.
SECTION 1.7
Integrator reduces program development by 90%
When integrators or end users build libraries of reusable functions, Logix makes it easier to reuse this
library. The reduction in programming time for specific parts of an application, such as replicating several
instances of complex processes (multiple blending tanks, for example) is proportionate to the number of
identical processes in the system. In an application that required nine blending tanks, an integrator
described how he first wrote and debugged the control strategy for the most complex tank in the system.
Control for the remaining eight tanks, which were near-clones of Tank #9, required very few edits, which he
then programmed and debugged in a fraction of the time required to program the first tank.
VALIDATION: Real-World Examples – 6.1
6.1
SECTION 1.10 SECTION 3.6
Cut programming time in half - reduce program overhead Reduce downtime with diagnostics
by more than 25% A system integrator observed that “. . .with traditional PLC systems, writing the extra code to initially detect
A large packaging machine OEM discovered that “. . .programming time was essentially cut in half. . .”. They and then annunciate potential failures was often so difficult that (it) was left out.” With Logix and Kinetix,
explained that their traditional approach required two separate controllers (sequential and motion) each with detection is handled by the Kinetix servo drive. The programmer is required to write only the annunciation
its own software, programming language, hard wiring, communications, and synchronization logic. As much routines. Diagnostic information is provided by the Kinetix device.
as 25% of the programming in each controller was required to integrate the controllers. Logix eliminated
writing complex synchronization programs. And with Logix, this OEM noted that servo motion programs such
as blank feed and partition feed took significantly less time to program. “Programming time was essentially
cut in half. We simply cut, pasted and renamed. Programming took an hour instead of several hours”.
MAINTAIN
Use superior diagnostics, reduce
downtime for greater productivity
INSTALL
Minimize wiring, enjoy a faster start-up
with an integrated control system SECTION 4.2
Decrease defective module replacement time by at least 30 minutes
Without the ADR feature, a Logix integrator estimated conservatively that it would take a technician using a
SECTION 2.1 programming terminal 30 minute to replace a smart module. This takes into consideration booting up,
Reduce wiring costs by more than 90% connecting, and downloading to the replacement module. With ADR, defective smart modules can be
An experienced PLC/motion programmer stated that “. . .SERCOS definitely reduces the number of replaced as quickly as older “dumb” modules.
terminations compared to a traditional PLC, motion controller and servo drive combination”. (See comparison
in section 2.1) SECTION 4.4
Reduce troubleshooting costs by several hundred dollars per call
When on-site troubleshooting calls are reduced, the cost of system maintenance is reduced. A Logix
integrator estimated on-site technical assistance costs average as much as $100 per hour. A problem that
OPERATE requires on-site troubleshooting may cost $1000 per day, because of air fare and per diem. With remote
diagnostics, on-site visits are dramatically reduced. One manufacturing customer using Logix stated “. . .
Improve performance, access information
troubleshooting can now occur at our facility via direct remote access. This allows engineers at remote
from the entire system
locations to accomplish changes or enhancements over the phone line, greatly simplifying system updates
and troubleshooting in a time-saving manner. . .”
SECTION 3.4
Reduce programming 30% by using NetLinx networks
When writing a control program to support an application, a portion of the code is used to control the actual
machinery and a portion of the control program is used to support communication - that is, moving data from
one network to another. A typical system can use 30% or more logic for this simple task. NetLinx eliminates
this extra code. Programs are smaller and are much easier to interpret. The user saves time, money
computing power and gets improved controller performance.
Allen-Bradley, CompactLogix, ControlLogix, DriveLogix,
FactoryTalk, FactoryTalk Audit, FactoryTalk Directory, FactoryTalk
Live Data, FlexLogix, IntelliCENTER, InView, Kinetix, PanelView
Plus, PLC-5, PowerFlex, PowerFlex 700S, RAAMP, Rockwell
Automation, Rockwell Software, RSAutomation Desktop,
RSBizWare, RSBizWare Historian, RSBizWare MaterialTrack,
RSBizWare PlantMetrics, RSBizWare Scheduler, RSLinx, RSLogix,
RSLogix 5000, RSMACC, RSNetWorx, RSTestStand, RSView,
RSView Machinery Edition, RSView Studio, RSView Supervisory
Edition. SLC, SMC, SoftLogix 5800, TechConnect, VersaView and
XM are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation

are property of their respective companies.
IA-BR002D-EN-PCoverev6.qxd 4/22/05 3:35 PM Page 1
INTEGRATED ARCHITECTURE
Saving time and money using Integrated Architecture
Publication XXX-XXXXX-XX-P – Month 200X — Supersedes Publication XXX-XXXXX-XX-P – May 200X Copyright ©200X Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Publication IA-BR002D-EN-P – April 2005 Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Printed in USA
Supercedes Publications IA-BR002B – EN-P – October 2003 and IA-BR002C-EN-P – January, 2005

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l FactoryTalk is a suite of services embedded in Integrated Architecture components that dramatically

INSTALL 5.1 What's your maintenance strategy?

Minimize wiring, enjoy a faster start-up with an integrated control system

BENEFITS OVER CONVENTIONAL SOLUTION

of languages Function Block Diagram

automatically creates canned

structures provide tags for status,

FactoryTalk-enabled system Program tags using

A conventional control system requires creating and maintaining two

BENEFITS OVER CONVENTIONAL SOLUTION

electrical design and program

BENEFITS OVER CONVENTIONAL SOLUTION

engineering and allows for

BENEFITS OVER CONVENTIONAL SOLUTION

l Allows for standards to be used consistently throughout an organization

l Allows restoring any historical version of an industrial automation project

PLC Servo controller Servo drive

Extend the functionality As a distributed I/O network . . . There’s no easier or

Kinetix Integrated Motion solution Integrated Architecture Solution

Save Panel Space

Fiber optic connector

For monitoring, the motor starter is equipped with an

from Rockwell Automation can optimize your automation systems and

Analyze BENEFITS OVER CONVENTIONAL SOLUTION

Simplify information access by using EtherNet/IP Solution

The actual user implementation may

BENEFITS OVER CONVENTIONAL SOLUTION

Define graphic displays once Integrated Architecture Solution

a distributed system system.

referenced, not duplicated, edits update automatically across the system.

Export the graphic display to a file.

To edit the graphic display, either

today’s needs; provide simple future

Assure virtually non-stop monitoring Integrated Architecture Solution

Motion control is often used in critical high-speed machines in

1 A filling machine uses a motion controller to

BENEFITS OVER CONVENTIONAL SOLUTION

Improve plant reliability through The XM Solution

ControlNet BENEFITS OVER CONVENTIONAL SOLUTION

l Combined condition monitoring and protection system in one

Today’s industries use a wide range of application types to produce their

Extend system visibility through

BENEFITS OVER CONVENTIONAL SOLUTION

Easy data access to diagnose

a central computer connected on

reduce lengthy set-up time involved when replacing damaged

1 Put the device on as an unused node on

2 Set the device address.

2 The DeviceNet scanner automatically

BENEFITS OVER CONVENTIONAL SOLUTION

Audit and manage changes to Integrated Architecture Solution

BENEFITS OVER CONVENTIONAL SOLUTION

Integrated Architecture Solution

What’s your maintenance strategy? Eliminate

Conventional Solution Industrial Network and Security Services

Validating the economic DESIGN

Integrated Architecture SECTION 1.3