OT Network and Disaster Recovery - ES&E Automation Expo 2025

Summary

This video covers various recovery and backup options for network devices, configurations, and switching hardware. It explains methods such as Device Manager for simple, no-cost backups, SIP Protocol and AOP for adding configurations to controllers, and advanced tools like Cisco Catalyst Center and Rockwell’s Asset Center for more robust management. The focus is on ensuring quick recovery in case of failures, with a look at the advantages, limitations, and security concerns of each method. The video also highlights the importance of using automation and AI for monitoring network health and securing configurations.

Takeaways

• 💾 Network infrastructure is critical to facility operations, making reliable backup and recovery essential to minimize downtime during failures.
• ⚙️ Four main recovery methods were discussed: Device Manager, CIP (Common Industrial Protocol) with AOP (Add-On Profile), Cisco Catalyst Center, and FactoryTalk AssetCenter.
• 🌐 Device Manager is the simplest and most cost-effective option, offering a user-friendly web interface for those unfamiliar with command-line tools.
• 📤 Device Manager supports configuration backup and restore through protocols like TFTP, SFTP, FTP, and HTTP, allowing easy transfer of switch configurations to a secure server.
• 🔐 Security is emphasized — backup locations must be protected, and physical panels and devices should be locked and password-protected to avoid unauthorized access.
• 🧩 The Stratix Add-On Profile (AOP) allows users to integrate switch configurations directly into Studio 5000 controller projects, simplifying centralized backups.
• ⚠️ AOP integration consumes a controller connection and requires firmware compatibility, but it simplifies backup since only one controller project file needs to be saved.
• 💡 Cisco Catalyst Center (formerly Cisco DNA) provides an advanced, subscription-based network management solution offering automation, monitoring, AI-driven anomaly detection, and zero-trust security.
• 🗄️ FactoryTalk AssetCenter serves as Rockwell Automation’s comprehensive asset management system, backing up various industrial assets like switches, controllers, and drives, using a SQL database.
• 🔎 AssetCenter features automated disaster recovery, change detection, and version comparison tools that notify users of configuration changes and highlight differences between file revisions.
• 🧠 The overall theme stresses layered protection — combining secure access, automated monitoring, and centralized backup systems to ensure fast, safe recovery from network disruptions.

Q & A

Why is network infrastructure and switching hardware critical for facilities?

Network infrastructure and switching hardware are the backbone of operations in a facility. Without a functioning network, the facility cannot perform its tasks, making it crucial to have reliable backup and recovery options in place.

What is the main reason behind the need for disaster recovery?

The main reason for disaster recovery is to ensure that systems can be restored quickly after an event like a failure or damage, so that operations can continue with minimal downtime.

What is Device Manager, and how does it help in network recovery?

Device Manager is a simple, web-based tool that allows for easy backup and recovery of device configurations. It enables users to copy files from devices and restore them using protocols like TFTP, FTP, or HTTP, offering a straightforward way to restore network devices without deep technical knowledge.

What is SIP protocol, and how does it relate to network backups?

SIP (Common Industrial Protocol) is a communication protocol layered on top of Ethernet IP. It facilitates the communication of network devices, and is used in some network management tools for configuring and backing up devices.

What does AOP (Add-On Profile) refer to in the context of backup and recovery?

AOP is an interface that allows users to add a new device to a network controller's configuration in Studio 5000. It provides a graphical user interface for managing device configurations, making it easier to back up and recover specific devices as part of the broader system setup.

What is the downside of using AOP for backing up switches?

The downside of using AOP for backups is that it requires a connection to the PLC, which may be an issue for some customers. Additionally, managing firmware versions and ensuring compatibility between devices can be challenging.

What are the features of Cisco Catalyst Center (previously Cisco DNA)?

Cisco Catalyst Center is a network management platform that enables automation for configuring new switches, monitoring network security, managing trust policies, and using AI to analyze traffic patterns. It helps identify unusual network activity, such as potential viruses, and ensures secure communication between devices.

How does Rockwell Automation’s Asset Center assist with disaster recovery?

Asset Center is a comprehensive asset management solution that allows users to back up configurations for various devices like controllers, switches, and drives. It can also automate disaster recovery by periodically checking devices for configuration changes, and notifying users of deviations. This helps ensure that systems are always up to date and secure.

What is the role of SQL in Asset Center?

SQL serves as the database backend for Asset Center, storing and managing the backup configurations of various assets. It helps facilitate the tracking and recovery of these configurations by organizing data in an efficient and accessible manner.

What are the benefits of using the comparison tools in Asset Center?

The comparison tools in Asset Center allow users to compare different versions of configurations, helping identify changes made to devices like controllers or switches. This is useful for auditing purposes, as it lets users track unauthorized changes or ensure that updates are applied correctly.