Profibus DP PDF 1

PROFIBUS Introduction
PROFIBUS & PROFINET International (PI)

2
International creator, maintainer, and promoter of open, industrial

communication standards PROFINET and PROFIBUS
Founded 1989
Organization Technologies
27 Regional
PI Associations
PI Competence
Centers
62 Fieldbus Ethernet
10 33
Proxy
PI PI Technology
Test Labs Training Centers
WGs
Sensors & Actuators
PI= PROFIBUS & PROFINET International
1
PI North America
3
North American Regional PI Association

Founded in 1994 as PROFIBUS Trade Organization
Non-profit and member-supported
Support in North America:
PICC PITC PITL

PROFI Interface Center    PICC = PI Competence Center
PITC = PI Training Center
JCOM Automation   PITL = PI Test Lab
Phoenix Contact Software 

HMS 
What’s a fieldbus?
4
A Fieldbus is a digital, serial, two-way, multi-drop communication link among controllers and its remote I/O, sensors,
actuators and inter-networking components.
In comparison to standard Local Area Networks (LAN), fieldbuses are specialized for the rugged industrial environment,
determinism, bus powering, etc.
2
Before Fieldbuses
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Process Controller
Direct Wired System
(PLC, DCS, or PAC) PLC = Programmable Logic Controller
DCS = Distributed Control System
PAC = Programmable Automation Controller
Fieldbuses
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3
Fieldbuses
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Architecture
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4
Why use a fieldbus?
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Engineering and documentation

Easier configuration
Easier to use and up-to-date documentation
Hardware
Less hardware: I/O, terminal blocks, enclosures, barriers, wire
Installation
Easier, quicker, and less time-consuming
Commissioning
Faster
Maintenance/Operations
Improved availability & reduced down time
Improved asset management
Manufacturing Flexibility
Changes are implemented rapidly
PROFIBUS and PROFINET Timeline

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1987 1990 1995 2000 2005 2009
In 1987 the German Federal Ministry for Research and Technology requested a collaboration project called “Field Bus”
13 Companies and 5 Universities developed an open field bus under the name PROFIBUS for PROcess FIeld BUS based
on the ISO/OSI reference model
ISO = International Standards Organization

OSI = Open Systems Interconnection
5
PROFIBUS and PROFINET Timeline
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1987 1990 1995 2000 2005 2009
PROFIBUS DP for discrete IO (1993) PROFINET for PROFIsafe & PROFIdrive (2005)
DP = Decentralized Peripheral PROFIBUS PA Profile 3.02 (2009)
DP-V0 PROFIenergy (2010)
PROFIBUS PA for process instruments (1996) PROFINET for Process Automation (2011)
PA = Process Automation
DP-V1 and PA
PROFIBUS for PROFIsafe & PROFIdrive (2001)
DP-V2
PROFINET for CBA and IO (2001)
CBA = Component Based Automation
PROFIBUS Key Application

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Factory automation
Vehicle manufacturing
Bottling plants
Warehousing systems
Process automation
Chemical industry
Petrochemical industry
Paper and textiles
Power stations
Drive technology
Machine tools
Packaging machines
Paper production
Hybrid applications
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PROFIBUS DP and PA
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PROFIBUS is mainly used for high speed input/output devices and to link intelligent devices such as drives.
It can use different physical layers such as RS-485 (most common), wireless or fiber optics.
PROFIBUS PA refers to the following additional features:
Bus powered by using the Manchester encoded Bus Powered (MBP) physical layer according to IEC 61158-2
Intrinsically safe design
Configuration over the bus
Device profile
DP = Decentralized Periphery
PA= Process Automation
PROFIBUS DP
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Open, international standard (IEC 61158)

ISO/OSI
Serial Fieldbus
7 Application layer
RS-485 transporting 244 bytes at up to 12Mbit/s
6 Presentation layer
Uses layers 1, 2, and 7 of the ISO Model
5 Session layer
4 Transport layer
3 Network layer
2 Data link layer
1 Physical layer
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PROFIBUS PA
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Open, international standard (IEC 61158)

Serial fieldbus
Same protocol as DP, different physical layer: MBP at 31.25kbit/s
Suitable for hazardous environments
SD LE LEr SDr DA SA FC DU.. FCS ED
P SOF SD LE LEr SDr DA SA FC DU.. CRC EOF
PA= Process Automation

MBP = Manchester-encoded, Bus-Powered
PROFIBUS DP- Decentralized Periphery
Network Design
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PROFIBUS DP Project Steps
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Plan/Design Configuration Installation Commissioning Maintenance
• How • Configure • RS485 • Using a • Diagnostic

PROFIBUS your Network Signaling Physical Information
works Layer
• Fail to known • Segmentation • Using HMI’s
Bus Tester
• Plan and state Review
Design your • Using other
• Demo of • Grounding
Network Diagnostic
Configuration
• Cables and tools
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Controller - Device Concept

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Eng
Active Station(s) Station
PLC/
PLC/
DCSCS
PROFIBUS
Passive Stations (Field Devices)

Outputs Request
Inputs Response
Cyclic Channel – I/O Data Exchange Acyclic Channel – Parameter Access
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Controller - Device Concept
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 Multiple Controllers
Can Share the Bus
 One Controller May
Read Data From
Another Controller’s Active Stations
Devices PLC/
PLC/
PLC/ DCS
BUT
DCS
DCS
 Only One Controller
Can Write to the
Outputs of a Specific
Device (Must Know
Who Is Controlling PROFIBUS
Outputs)
Passive Stations (Field Devices)
Outputs
Inputs
Cyclic Channel – I/O Data Exchange
PROFIBUS Features
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Cyclic and acyclic channel accesses

Cyclic channel is used for high-speed I/O Data Exchange and Is automatic when PROFIBUS communication is activated
Acyclic channel communication is not automatic but is used for on-demand access to parameter data
Via PLC Instruction
Engineering tool request
Cyclic Communication Cyclic/Acyclic Communication
I/O Cycle Time -

Cyclic Communication
Acyclic Channel –
Parameter Access
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PROFIBUS Features
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High-speed decentralized periphery (DP) I/O data exchange features

All field devices have the same priority
Every device is scanned every cycle
Configuration is permanent and cyclic
Devices to be controlled are specified
Amount of I/O data to be exchanged is specified during configuration
Controllers with Configuration-in-Run (CiR) support on-line configuration changes
Communication rate up to 12Mbits/s
1.5Mbits/s most frequently used
PROFIBUS Features
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PROFIBUS DP and PA utilize the same protocol

DPV0 Is the base protocol for cyclic I/O and diagnostics
Exchanging inputs/outputs
Reporting diagnostics such as wire break, short circuit, etc. DP – Decentralized Periphery
DPV1 extensions to DPV0 support acyclic channel and alarms PA – Process Automation
On-demand access of device parameters

Reading measuring units, i.e., atm, mm Hg, mm H2O
Setting alarm limits, i.e., HI, LO, HI-HI
Reporting limit alarm, etc.
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PROFIBUS Project Steps
23

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Plan and Design DP Network

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Design considerations
Do I have any very long distances to cover?
How many devices will I have?
What communication medium/media will I use?
Are there any high-EMI areas?
Does my architecture require the use of “stub” lines?
What is the required I/O update cycle time?
How many networks do I need?
Many of these constraints/requirements are inter-related
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Segment and Network Lengths
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We need to start with learning some definitions

What constitutes a network?
In the simplest case, a network is a single RS485 length (segment) of copper cable
What constitutes a copper segment?
The longest run of copper cable possible at the baud rate used without too much signal degradation from attenuation
Higher baud rate signals are attenuated and distorted more rapidly than lower baud rates
A run of copper cable with no more than 32 devices to prevent loss of signal integrity due to loading
Every device adds capacitance and loads down and distorts the signal
The maximum length of a segment supports a fully loaded segment, i.e., 32 devices

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What are the constraints on segment length?

The following table gives the maximum RS485 copper segment lengths for the PROFIBUS baud rates
What if our network needs to be longer than a segment?
Baud Rate (kbits/s) Max. Segment Length
9.6 1,200m/3,934ft
19.2 1,200m/3,934ft
45.45 1,200m/3,934ft
93.75 1,200m/3,934ft
187.5 1,000m/3,278ft
500 400m/1,311ft
1,500 200m/656ft
3,000 100m/328ft
6,000 100m/328ft
12,000 100m/328ft
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Number of Devices on a Segment
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What are the constraints on the number of devices?

The EIA/TIA 485 specification says that 1 RS485 transmitter can drive 31 RS485 receivers
Therefore, a maximum of 32 RS485 devices are permissible on a single copper segment
What if we have more than 32 devices?
What constitutes a device?
Any component attached to a segment that has RS485 circuitry counts as one of the 32 devices.
PLCs
I/O devices
HMIs
Repeaters
PROFIBUS DP/PA gateways
Fiber optic repeaters (OLMs)
Bus diagnostic tools
Basically anything with a copper connection
The one exception is an active termination box

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What if the total network must be longer than the segment length allowed at the baud rate used?
What if the total number of devices is greater than 32?
The network is “segmented” by connecting the previous segment having the diminished or distorted signal to a Repeater to refresh
the signal.
Refreshes the voltage level
Reshapes the waveform
R
Diminished/Distorted RS485 Signal e
p
e
a
t
e
r
14
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The network is “segmented” when the maximum segment length for the baud rate is reached or when 32 devices are
attached…either situation requires segmentation no matter which is reached first.
Network May Consist of

Multiple RS485 Segments
Specific Length=
32 Devices=Segment Segment

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Example segmentations
R
e
12,000kbits/s p
Controller e
a
100 meters t
e
r
No devices
R
e
12,000kbits/s p
Controller e
a
50 meters t
e
r
31 devices in first 50 meters
Next device at 60 meters
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Example segmentations
R
e
12,000kbits/s p
Controller e
a
100 meters t
e
r
31 devices in first 50 meters
Next device at 130 meters
Communication Path Lengths

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There is a limit to the number of repeaters that can be used in a communication path between a PLC and a device.
The reason is to avoid the possibility of timing problems.
There is a slight time lag through each repeater on outgoing messages from a PLC and incoming messages from the device.
A PLC will wait only a specific amount of time for a response from the device.
A vendor’s repeater manual will typically list a “maximum cascading depth” that can be tolerated without the possibility of timing problems.
For example, Siemens repeaters have a limit of 9 and Procentec repeaters have virtually no limit
Some other repeaters have a limit of 3
Slower electronics
Don’t amplify the voltage…just reshape signal
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Cascading Repeaters
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PROFIBUS – DP segment and communication path length

Using 9 Cascaded
12,000 12,000 12,000 12,000 Repeaters.
12,000
Check Max. Cascading
10,000 Depth!!!
10,000
8,000 Segment [m]

Network [m]
6,000
Length in Meters 4,000
4,000
2,000
2,000 1,200 1,200 1,200 1,200
1,000 1,000 1,000
400 200 1,000
100 100
0 100
9.6 19.2 45.45 93.75 187.5 500 1,500 3,000 6,000 12,000
Baud Rate (kbits/s)
Total Repeaters In A Network

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Although a single communication path has a cascading depth limit, there can be more repeaters used in the entire
network.
Controller
Device
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Network Segmentation
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DP network segmentation example
Address #1 Address #31 Address #32 Address #61
No Address OLM: Fiber optic repeaters
Address #121 Address #92 Address #91 Address #62

No Address
No Address
Up to 32
Devices Per
Segment
Address #122 Address #125
No Address = Repeater
= OLM
PROFIBUS DP Communication Media

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What communication medium/media will I use? Wide range of available media and technologies.
Copper is the most commonly-used with a wide variety of connector technologies
Almost all devices have a copper connection
RS485 signaling technology used
Wide variety of connectors available
Fiber optics
Long distances with high-quality fiber
Variety of topologies and redundancy
Immune to ground plane differences
Suitable for use in high EMI areas
Few devices have a direct FO connection
Infrared communicators
Good for lateral motion
Limited to about 15m/50ft distances
Maximum baud rate = 1,500kbits/s
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PROFIBUS Communication Media
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Laser communicators.
Good for linear, in-line motion
Can communicate to about 400m/1,311ft
Typically used to eliminate trailing cable
Radio transceivers.
Some models communicate up to several miles
Radio-radio communication generally at baud rates of 9.6 or 19.2kbits/s
Two general types available:
Transparent – each device is front-ended by a transceiver
Non-transparent – transceiver acts as a master to devices behind it and must be configured
PROFIBUS Communication Media

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Other communication technologies:
Slip rings.
For rotating machinery even at up to 12Mbits/s
Hanging conveyor power rails.
Limited to 1.5Mbits/s
For moving assemblies from workstation to workstation
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PROFIBUS Physical Layers
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Most commonly used physical layers will be covered in this class

RS485 on copper
Already covered basics needed for planning and design
Fiber optics
MBP on copper – used by PROFIBUS PA and Foundation Fieldbus (FF)
Use of Stub Lines

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What is a stub/spur/tee line?

Direct connection into main trunk/segment, basically a splice or the electrical equivalent of a splice
Why are stub lines “bad”?

Stub lines generate reflections on the bus and can cause communication problems at higher baud rates
All energy from a waveform is not absorbed at the end of a segment and “bounces back” or reflects, possibly corrupting the signal
being sent from the transmitter
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Use of Stub Lines
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For baud rates above 500kbits/s, it’s safer to use a repeater to facilitate a branch away from the main trunk line.
There will never be a problem to extend the segment or increase the baud rate because it is not a spur/stub line
Repeater product availability from Siemens, Procentec, Phoenix Contact, Kunbus, Helmholz, Indusol, Hirschmann, etc.
Procentec Phoenix Contact

Siemens
Use of Stub Lines

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Some architectures are facilitated by using stub lines.

Drops from a conduit adapter to a valve, for example, to maintain waterproof integrity of the conduit
Eurofast or Minifast
Stub lines from a trunk line to removable buckets in an MCC, for example Connector – Cable to valve
Both architectural examples seem to have some justification, although most MCC wiring uses daisy-chaining
Architectures are possible using stub lines; however, the baud rate restrictions from the PROFIBUS standard must be
observed.
The standard states the restrictions in terms of the total amount of capacitance allowed due to the total of stub lines on a segment
for a given baud rate
Using the Type A cable capacitance of 30pF/m, it’s easy to convert these allowed capacitances to distances,
as shown in the next table
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Use of Stub Lines
43
Table of total length of allowed stub lines at the different baud rates.
Remember that this is the total for ALL stub lines…not the limit for each individual stub!!
600
550
500
500 500
450
400 Total of Allowed Stubs [m]
350
300 300
250
200
Meters 150
100
100
50 33 20 6.6 0 0
0 0
0
5
00
6
.2
50
7.
.4
.7
50
00
00
9.
19
,0
[kbaud]
45
93
18
1,
3,
6,
12
Extensive Use of Stub Lines May Prevent Later Expansions to the

Network and/or Preclude Higher Baud Rate Operation.
Use of Stub Lines

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Stub lines result in “lumped” capacitance at the point of the stub line
35pF Equivalent 35pF
Normal Device
Capacitance Lumped Capacitance = L*30pF + N*35pF
L L = cable length in m
N = no. of devices
35pF
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Fiber Optic Media
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Least expensive,
Plastic lowest performance,
Low performance, large diameter plastic core easiest to use.
Plastic Clad Silica/Poly Clad Fiber (PCS/PCF)

Medium performance, intermediate diameter glass core
Cladding is plastic or lower grade glass
Single Mode Glass Fiber

High performance, small diameter glass core
Most expensive,
Cladding is less pure glass than glass core best performance,
hardest to use.
Use of Fiber Optic

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Fiber optics - advantages

Noise immune – resistant to EMI
Potential difference independent
No worry about ground current loops
ALWAYS Use Fiber

Building A Building B
Longer Distances
Line, ring, redundant ring and star configurations are possible
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Use of Fiber Optic
47
Cable lengths with fiber
Cable Spacing, Core/Cladding (µm) Distance Between FO Operating Wavelength

Repeaters (m) (nm)
Plastic, 980/1000 50 - 80 650
PCF/PCS, 200/230 300 - 400 650
Multi-Mode Glass, 62.5/125 3,000 860
Multi-Mode Glass, 50/125 3,000 860
Becoming more popular with use of VCSELs

*
Single-Mode glass, 10/125 15,000 1300
*VCSEL is Vertical Cavity Surface Emitting Lasers
Use of Fiber Optic

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Fiber optic – redundant ring

Used on US Navy carriers
PROFIBUS FO -
Glass, PCF or Plastic
Redundant
OLM Paths
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Use of Fiber Optic
49
Fiber optic backbone

Used in high EMI areas
Induction furnaces, high-HP motors, etc.
Areas having tendency for grounding problems
Fairly short copper runs with a few devices.
Fiber Optic Repeaters (OLMs)
Instruments In Explosive Areas

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Do I have explosive areas into which instruments must be installed?

Must decide whether to use traditional protection technologies, e.g., purged cabinets, pressurized cabinets, oil/sand submersion,
etc., or intrinsically safe technology
Can choose to do “business as usual” by using the older technologies
OR
PROFIBUS PA (or FF) can be used, both of which use MBP bus physics
Install devices directly into explosive areas without housing the devices and be able to perform “hot” maintenance
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Address Assignment
51
PROFIBUS DP address assignment

Assignment of addresses to the devices has no effect on bus performance
However, as an aid in commissioning and later maintenance, planned address assignment can be an aid
Consider assignment of address ranges based on the segmentation, for example:
First segment: addresses 1 – 19
Second segment: address 20 – 39
I/O Cycle Time

52
What do I need to consider to determine the I/O cycle (update) times required?
The PLC/DCS control cycle time
Should have several I/O updates for each control cycle
Required I/O response times
Input to output
What do I need to consider that affects the DP I/O cycle time?

The communication baud rate
Higher baud rates = faster I/O cycle times
The total number of devices to scan each cycle
More devices = longer I/O cycle times
The total number of bytes of data (outputs + inputs) transferred each cycle
More data = longer I/O cycle times
The total number of networks
More networks for same number of devices or the same amount of data = faster cycle times
Communication with PA sub-networks
Certain DP/PA couplers can drastically slow down the DP cycle time (covered in PA section)
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I/O Cycle Time
53
What do I need to consider to meet the I/O cycle (update) times required by my control cycle time?
The effect of communication baud rate on cycle time is pretty much self-explanatory
The effect of more/less devices to scan each cycle is also pretty much self-explanatory
The effect of more/less data to be transferred each cycle is also pretty much self-explanatory
The effect of the total number of networks may not be self-explanatory
Some DP/PA couplers are “dumb” and require slowing the baud rate on the DP network to 45.45kbits/s or 93.75kbits/s – more details
later
I/O Cycle Time

54
Up to 126 devices are possible on a single PROFIBUS DP network

PROFIBUS Utilizes Addresses 0 – 127
Address 127 Is Used for Broadcast Messages
No Device Can Have Address 127
Address 126 Reserved for Devices Without Address Switches…Cannot Exchange I/O Data
Address 0 Frequently Used By Engineering, Programming or Configuration Tools
Some cannot have their address changed
Only addresses 1 – 125 can be used for active devices exchanging I/O data…typically one controller and the rest devices
More than one controller is possible – HMI devices typically sit on the bus as a controller device
Device address assignment has no effect on bus performance
Address assignment has no effect on bus performance since the controller only attempts communication with addresses that are
assigned in the configuration
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I/O Cycle Time
55
Assume that our required I/O cycle time is 10ms

Assume a single network with one controller PLC and 50 devices having one byte of output and one byte of input data
each
Some PROFIBUS configuration tools calculate an estimated I/O cycle time for the configuration and display it in the “bus parameters”
One such configuration tool gave an estimated cycle time for the above configuration of 12.7ms at 1.5Mbits/s
I/O Cycle Time

56
What are the primary things we can do to meet the requirement of 10ms?
Increase the baud rate
Split the devices out onto more than one network
Increasing the baud rate to 12Mbits/s in our configuration tool gave an estimated I/O cycle time of 4.1ms
28
I/O Cycle Time
57
Splitting the 50 devices across two networks of 25 devices at 1.5Mbits/s with our configuration tool gave an estimated
I/O cycle time of 6.5ms
The two separate networks are being scanned in parallel, cutting the I/O cycle time approximately in half
PLC/
DCS
Most PLCs/DCSs accommodate
multiple PROFIBUS controller cards
25 Devices
25 Devices

58

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
29
Device Selection: Devices
59
Choose your PROFIBUS devices

Choose devices that best fulfill your specific application requirements
Look for features that make your job easier
Soft starter
Intelligent breaker
Good diagnostic capabilities
Devices should be certified by an accredited PI test lab – such as the one in Johnson City, TN
Certified to meet the IEC 61158 standard
PROFIBUS communication won’t fail under some “weird” circumstance
Device Selection: Controller

60
Choose your PROFIBUS controller

Must be able to handle all requirements of the devices, i.e., bytes or words of input and output data, amount of parameter data, etc.
Some low-end controllers only support the minimum stated in the PROFIBUS standard
32 bytes inputs and outputs
32 bytes of parameter data
Controller should be certified by an accredited PI test lab
30
Configuration Software Selection
61
PROFIBUS configuration software requirements

Should be user-friendly and able to handle all device requirements, e.g., large number of user-selectable parameters
Should utilize the textual entries from the device GSD file for listing the parameters by name and listing the possible values for
parameter settings
Some configuration tools require the user to dig through a manual to determine what parameters the device has, the appropriate
flag/field settings for parameter selection and then require the user to input raw hexadecimal values

62
Parameter selection
This
This
Or
This?
This
31
Device Selection
63
How do I find available devices?

Product Finder at profibus.com

64
How can you find out if a device is certified?

If there is a write-up in the product guide, there will be an indication if the product is certified
It is the vendor’s responsibility to put a write-up in the product guide
If there is no write-up, you can ask the vendor to provide a copy of one of the following:
The certificate issued by PI showing the product is certified
The test report from the lab that tested the product, which will have a pass/fail recommendation
32
Network Configuration

66

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
33
System Configuration
67
Plug and Play With Electronic Device Data Sheets

PROFIBUS
Configuration Tool
•Select Master
•Assign Address
•Select Devices
•Assign Address
•Configure I/O
•Set Parameters
PLC/
PLC/
DCS
DCS
Electronic Device Data Sheets (GSD, GSE, GSF, GSG, GSI, GSP, GSS Files)
PROFIBUS
GSD – General Station Description
GSD Files
68
Plug and play with electronic device data sheets – gsds

Provided by the device vendor – check web site
Describes device’s PROFIBUS features
PROFIBUS Ident number
What baud rates are supported
What I/O configurations are supported
What plug-in modules are available
Any special PROFIBUS features supported
Fail-to-Known-State
SYNC/FREEZE
Any PROFIBUS protocol extensions supported
DPV1
DPV2
Any PROFIBUS profiles supported
PROFIdrive
PROFIsafe
34
GSD Files
69
Example of a GSD file

GSD
GSD Revision According to Standard

Vendor/Manufacturer Name
Device Name (Displayed in Config Tool)
Unique ID Number of Product

 Mandatory for Class 1 and devices
 Issued by PI
Services Supported (0=DP; 1=DPandFMS)

Type (0=Device; 1=Master)
Supported Transmission Rates and Related

Timing Parameters
GSD Files
70
Example of a GSD file

GSD
1=Freeze of Input Data Supported
1=Synchronization of Output Data

Supported
1=Transmission Rate Detected by Device
0=Address Can NOT Be Set Via PROFIBUS
1=Station Accepts Plug-In Modules

Length Definitions for Modular Stations
Maximum Amount of Diagnostic Data

Reported by the Device
Used by Configuration Tool to Categorize
Devices in the Hardware Catalog
35
Startup Sequence
71
Startup sequence - high-speed data exchange

I/O configuration and parameter data must be downloaded to the devices
Power ON/ Power ON/Reset of

Reset Master or Device
Parameters selected during
Parameterization configuration by the user are
downloaded into the device for
processing and validation
I/O Configuration data selected
I/O Configuration during configuration by the user
are downloaded into the device for
processing and validation
Data Exchange Cyclic Data Exchange (I/O Data)

And Field Device Reports Diagnostics
Startup Sequence: Parameterization

72
Device parameterization
Select parameters with configuration tool
Power ON/
Reset
Parameterization
I/O Configuration
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gadfgsadfhsf ghjjsff ghsf gh gadfgsadfhsf ghjjsff ghsf gh
fdhsdldajhtvi ertivetv ert fdhsdldajhtvi ertivetv ert
34524 34524
575687356nj 8467k nggnhngjt 575687356nj 8467k nggnhngjt
rby5yik57859mnnbvt 456hn, rby5yik57859mnnbvt 456hn,
g76nkbvijyuftis dt0iewryt9ei uoriy g76nkbvijyuftis dt0iewryt9ei uoriy
rywkrowrgowrtohworthorthwrth rywkrowrgowrtohworthorthwrth
rthwrthrwthtryjtyjyuky rthwrthrwthtryjtyjyuky
tyjy7u79jtyu568566ut tyjy7u79jtyu568566ut
rtjhyuiuikujkhyjiyuiy uii rtjhyuiuikujkhyjiyuiy uii
thjyukiuio7ujty ujytuoiuk y thjyukiuio7ujty ujytuoiuk y
tyjyukuikyukuiluili ui oliuiluii l tyjyukuikyukuiluili ui oliuiluii l
6buhyijtiu8o67m8m 747567n8 6buhyijtiu8o67m8m 747567n8
567n75567nm78m78, om87o, 567n75567nm78m78, om87o,
56nu78m,,9o,0p.90. p;0;.;’-;/ 56nu78m,,9o,0p.90. p;0;.;’-;/
Data Exchange
Fewer DIP Switches - NO Handheld - NO Extensive Additional Documentation

User Defines Every Function in ONE Tool.
36
Startup Sequence: Parameterization
73
Device parameterization
Download parameters to device
Power ON/ Parameter Download (Up to 244 Bytes)

Reset
Parameterization
Controller Device
 Features Implemented in Device
I/O Configuration  Described in GSD File
 Processed by Configuration Tool
 Selected at Configuration
Data Exchange
 Examples:
 Enable Channel Diagnostic
 Operation Range for Analog Channels
 (e.g. ±10V or 0..10V)
 Fail-to-Known State Behavior (e.g. Hold Last
Value)
= Parameterization Data = Confirmation (Data Received)
Startup Sequence: I/O Configuration

74
Device I/O configuration

Describe I/O data to exchange
Power ON/
Reset
Parameterization
I/O Configuration
Data Exchange
37
Startup Sequence: I/O Configuration
75
Device I/O configuration

Download description of I/O data to exchange
Configuration Download (Up to 244 Bytes)
Power ON/
Reset
Parameterization
Controller Device
 Possible I/O Selections Described in GSD File
I/O Configuration  Processed by Configuration Tool
 Selected at Configuration
 Examples
Data Exchange
 8DI (1 Byte), 8DO (1 Byte)
 2AI (2 Words), 2AO (2 Words)
 RS232 Interface, Counter Module
= Configuration Data = Confirmation (Data Received)
High-Speed I/O Data Exchange

76
High-speed I/O - data exchange

Up to 244 bytes of input data and 244 bytes of output data
Only transfer what is configured
Power ON/
Reset
Parameterization
I/O Configuration
Data Exchange Controller Device
= Output Data = Input Data
38
Use of Startup Sequence
77
Importance of startup sequence

Controller has all information stored in retentive memory to start up a failed device replacement
Parameters
I/O configuration
Plug ‘n Play Replacement!!!

78
Plug ‘n Play replacement of a failed device
PROFIBUS PROFIBUS
System
Device
Fails
39
79
Plug ‘n Play replacement of a failed device

Take same device from spare parts
Set address to that of the failed device
Rotary/DIP switches
Software
Connect to bus
PROFIBUS PROFIBUS
System New
Device

80
When the controller finds the replacement device

Sends startup parameters
Send I/O configuration
PROFIBUS PROFIBUS
System New
New
Device
Device
Plug ‘n Play Replacement!!!
40
81

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Fail-to-Known-State
82
State of outputs on failure– fail-to-known-state
What happens if my bus fails:

valve open, valve closed,
valve 1/2 open…???
41
Fail-to-Known-State
83
Optional feature for field devices

Specified in GSD File
Manufacturer has the capability to allow the end user to specify the action of device outputs on loss of communication
between controller and device
Clear the outputs
Hold outputs at the last value received (e.g., Valve 1/2 Open)
Set outputs to a specified value (e.g., Open or Close Valve Completely)
User defines action with configuration tool while setting up parameters
Fail-to-Known-State
84
42
85

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
System Configuration
86
Plug and Play With Electronic Device Data Sheets

PROFIBUS
Configuration Tool
•Select Controller
•Assign Address
•Select Devices
•Assign Address
•Configure I/O
•Set Parameters
PLC/
PLC/
DCS
DCS
Electronic Device Data Sheets (GSD, GSE, GSF, GSG, GSI, GSP, GSS Files)
PROFIBUS
GSD – General Station Description
43
Demo Rack
87
SIEMENS TURCK
PLC S7-315 I/O System
BL Compact
PHOENIX CONTACT
I/O ILB 24
SIEMENS
DP/PA Link
and Coupler
WAGO SIEMENS
I/O-System 750 SITRANS
Temperature
Transmitter
WAGO
I/O-System 767
Configuration Overview
88
44
Address Assignment
89
Example I/O Configuration

90
Compact Device
45
Example I/O Configuration
91
Modular Device
Parameter Assignment
92
46
Fail-to-Known-State
93
Bus Timing
94
High-Speed Data Exchange (DP) Timing

10 Stations With 2 Byte I/O (160 In/Output Signals)
Bus Cycle Time = 0.8ms
Estimated
Bus I/O Cycle Time
47
Installation

96

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
48
RS485 Signal
97
PROFIBUS copper uses RS485 signaling

Cable is a Shielded, Twisted Pair (STP)
Differential signal difference between the two signal lines (B-A)
Idle line is at a mark (One) state
B-Line drives positive from idle
A-Line drives negative from idle
Receiver measures difference
B
A
Idle Line
Typically 4V – 7V
RS –Recommended Standard
STP – Shielded Twisted-Pair
RS485 Signal
98
More noise immune than single-wire technologies which transmit and receive on one wire
RS485 uses two wires
Transmits and receives on both wires
Any noise typically couples onto both wires of the STP in the same way
Up to a limit, the noise differences out at the receiver
B Differential Signal
A (B-A)
RS –Recommended Standard
STP – Shielded Twisted-Pair
49
99

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice

100
The following table gives the maximum RS485 copper segment lengths at the PROFIBUS baud rates.
Baud Rate (kbits/s) Max. Segment Length
9.6 1,200m/3,934ft
19.2 1,200m/3,934ft
45.45 1,200m/3,934ft
93.75 1,200m/3,934ft
187.5 1,000m/3,278ft
500 400m/1,311ft
1,500 200m/656ft
3,000 100m/328ft
6,000 100m/328ft
12,000 100m/328ft
50
Number of Devices on a Segment
101
The EIA/TIA 485 specification says that one RS485 transmitter can drive 31 RS485 receivers
Therefore, a maximum of 32 RS485 devices are permissible on a single copper segment
What constitutes a device?
Any component attached to the segment that has RS485 circuitry counts as one of the 32 devices.
PLCs
I/O devices
HMIs
Repeaters
PROFIBUS DP/PA gateways
Fiber optic repeaters (OLMs)
Bus diagnostic tools
Basically anything with a copper connection
Exception is active termination box

102
The network is segmented when the maximum segment length for the baud rate is reached or when 32 devices are
attached…either situation requires segmentation no matter which is reached first.
Network May Consist

of Multiple RS485
Segments
Maximum Length=
New Segment
32 Devices=New Segment
51
Total Repeaters In A Network
103
Although a single communication path has a cascading depth limit, there can be more repeaters used in the entire
network.
Controller
Device
Use of Repeaters
104
PROFIBUS DP segments are joined with repeaters
Segment 1
Segments
Connected Via
Isolation Repeaters
Segment 2 Segment 2
52
Use of Repeaters
105
Branching structures built with repeaters instead of splices into the trunk line
Extension of Segment 1
Segment 1 Segment 1
Isolation Segments
Connected Via
Repeaters
Segment 2 Segment 2

106

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
53
Segment Grounding
107
PROFIBUS DP – RS485 copper......what else do we need to consider?
Segment
Grounding
Segment Grounding
108
RS485 copper - segment grounding

Grounding protects against high-frequency interference pickup and emissions
54
Interference From External Sources
109
Electrostatic injection
Capacitive coupling caused by nearby high voltage power lines
High Voltage
Interference source,
e.g., power cable Capacitive coupling between cables
Pickup
Electromagnetic injection
Inductive coupling caused by varying currents in nearby power lines
High Current
Interference source,
e.g., power cable
Inductive coupling between cables
Pickup
Reduction of Coupling
110
Shielding reduces coupling effects

Provides low impedance path to ground for any pickup
Ground wire should be as large practical
Ungrounded shield provides no protection
Interference
Interference source.
e.g., power cable
Pickup passes to ground via shield
Rs Rs Rs Pickup
  
Rs = Shield resistance
For PROFIBUS cable, Rs = 9.5/km
55
Segment Grounding
111
RS485 copper... Segment grounding

Each segment must have the shield grounded
PROFIBUS Recommendation – ground the shield at both ends or at multiple points of the segment, especially for Baud Rates > 500kbaud
Provides lower impedance paths for higher frequencies
Typically see all devices on a segment grounded regardless of the baud rate
Segment Grounding
112
RS485 Copper...Segment grounding – what about ground current loops?

Employ Multi-Point Grounding – Easy for PROFIBUS
Most PROFIBUS devices provide continuity between the metal shroud on a 9-Pin Sub-D Connector or M12 metal threads and
A device ground lug
A device metallic DIN rail connector
This continuity is not a requirement...check the device manual or ohm it out!!
Employ hybrid grounding
Utilize a separate potential equalization line (10-12 AWG) between grounding points with large potential differences
56
Segment Grounding
113
RS485 copper...Segment grounding – what about ground current loops?

Employing Multi-Point Grounding
If continuity is provided, grounding the lug or din rail connector provides a grounding point for the shield, making multi-point grounding
straightforward
Continuity
Continuity
Segment Grounding
114

Employ Hybrid Grounding
Capacitive ground to block DC potential but provide ground path for higher-frequency noise
•0.10nF
•1500V
57
Segment Grounding
115

Employ potential equalization line
10-12 AWG, as close as possible to PROFIBUS cable.

Star grounding
Segment Grounding
116
RS485 copper... Segment grounding

Ground the shield entering/exiting a cabinet
Provides a ground path for devices mounted on din rails
Provides possible shield grounding point
Grounding
Clamp
Cable Shield
Grind Off Paint,

Rust, etc.
RS485 Copper...Segment Grounding – what about ground current loops?
Ultimate Solution – use fiber optics
58
117

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
PROFIBUS Cables and Connectors

118
RS485 Copper...what else is there to address?
Use Appropriate
RS485 Cable
Rated for
PROFIBUS
59
PROFIBUS Cable
119
RS485 copper installation - use correct cable

Use approved PROFIBUS Cable
Capacitance: < 30 pF/m
Loop resistance: < 110 /km
Impedance: 135  - 165  (Nominal 150 )
Conductor area:  0.34 mm² (22 AWG)
Frequency : 3 - 20 MHz
Capacitance and impedance are most critical
Both vary with frequency (impedance until characteristic impedance is reached)
Capacitance is cumulative with distance
PROFIBUS Cable
120
RS485 copper installation - use correct cable

For a Greenfield Installation, Just do it!
If you have existing wiring, and it’s not cost-prohibitive to replace, Just do it!
If you have existing wiring, and it is cost-prohibitive to replace, Do some research.
How close are my cable parameters to PROFIBUS cable?
Do I really need higher baud rates? (>187.5 kbaud)?
Higher Cable Capacitance => Lower Baud Rates
Higher Cable Resistance => Shorter Distances
Use more repeaters for longer runs
60
Connectors for PROFIBUS DP
121
Connectors- two main types utilized

Directional 9-Pin Sub-D
Pins defined in the PROFIBUS Standard
Connectors with integrated termination are available
Inductors built in for higher baud rates
Decrease reflections above 1.5Mbits/s
Daisy-Chaining allows unplugging of devices without interrupting the bus
Shield is connected with the Sub-D shell
EuroFast (M12)
Pins defined in the PROFIBUS Standard
Frequently used in extreme environments
Connect sensors, actuators and PROFIBUS stations
Connectors for PROFIBUS DP

122
Other common types

MiniFast (7/8”)
Also used in extreme environments
Phoenix-Style Terminal Blocks
IP20
Screw terminals are seen with some drives and instruments
61
123

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Segment Termination
124
RS485 copper... Anything else to consider?
Segment
Terminations
62
Segment Termination
125
RS485 copper segment termination

Terminate both ends of a segment
Impedance Matching
Eliminates/diminishes reflections
Segment Termination
126
DP copper segment termination

Where do we get it?
63
Segment Termination
127
Termination
If device is not powered, the terminating and biasing resistor network is not fully active
Reflections may be generated due to impedance mismatch
Device Must Be Powered
First / Last Device Bus Cable to Other Devices

VP+5V (6)
Biasing Resistor 390 Ohm
B-Line (3)
Termination Resistor 220 Ohm
A-Line (8)
Biasing Resistor 390 Ohm
DP-GND (5)
(X) Pin in Sub D Connector
Reflections in General
128
RS485 copper installation - avoiding reflections

What Are They?
Unwanted signals, waves (fuzzy tv picture, echoes on phone)
Reflected in all directions from a particular point on the bus
Caused by an impedance mismatch
Can destroy telegrams
The level or existence is independent of baud rate but the risk of causing a problem increases at higher baud rates due to decreasing
bit times
Reflective spike is small (9.6kb = ~.1ms)

% of overall waveform Receiver Samples in Middle of Bit Time Low baud rate
Reflective spike is large % (12mb = 83ns)

of overall waveform High baud rate
64
Segment Termination
129

Use active termination box If PC Card would be last node
Some lose +5V to connector over a restart
Segment Termination
130

Use active termination box at spare drive at segment end in MCC Cabinet
Many times spares are powered off
65
Segment Termination
131
RS485 copper - termination example
PLC/
DCS
OLM OLM OLM
Segment Termination
132

Unterminated or improperly terminated segments is still one of the leading problems seen in the field
66
133

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Set Device Addresses

134
Set Controller address

The Controller address is defined when doing the configuration in the engineering software. There are no physical address switches
on Controllers.
Set device address
Most devices have DIP or rotary switches for their address setting
BEWARE - Some rotary switches use HEX
coding although the DP address is decimal
Some devices support changing their addresses over the bus (an optional service)
Such devices (should) come with the address pre-set to 126
67
135

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Installation: Best Practice

136
RS485 copper...Other rules to follow!
Proximity to Power
Cables
68
137
RS485 copper cable...Recommended air-separation distances from power cables

A frequent violation
>= 20 cm
Cable Cable Cable

Category I >= 10 cm Category II >= 10 cm Category III
•LAN Cables Shielded/Unshielded Shielded/Unshielded

•Communication Cables for >60VDC or Cables for >400V
Cables (PROFIBUS) >25VAC and <=400V
>= 50 cm
>= 50 cm
>= 50 cm
Cable
Category IV
Any of Categories I-III

at Risk from
Lightning

138
RS485 copper cable installation – cable tray usage.

If channeled cable trays are used, same cable categories can be bundled in a tray
Channels in metal trays are suitable for separation
Ground the cable trays – provides a big potential equalization line
Bond any joints together for continuity
Butt weld
Join with large gauge wire
69
139
Connectors/wiring
Interconnection Standard specifies: A to Green / B to Red
Leave 1 Meter between uncertified or uncertain devices or at baud rates > 187.5kbits/s
Avoids “lumped” capacitance
35pF 35pF 35pF 35pF … Electrical

Equivalent
n x 35pF
(n = no. of devices)
Device capacitances look like a single
“lumped” capacitance.

140
Connectors/wiring
No Sharp Bends – minimum bend radius typically 10 x cable diameter
Can crimp copper
Do not mix different cable types
Ensure that each segment has a piggy-back Sub-D connector at least at one end for connection of diagnostic tools
Better to have one at each end
When using insulation displacement (ID) connectors, make sure the scissor blades of the connector make good contact with the
copper wire
If possible, use connectors and cables from the same vendor
If possible, start with a new cable end when re-using an ID connector
Don’t use same cable end more than twice
Check continuity when re-using an ID connector
70
141
Terminations
Ensure terminations are at segment ends and that the terminations will have constant power
Make sure that there are exactly two terminations per segment…no more and no less!
Bus segmentation
Make sure that all segments meet the length restrictions for the baud rate
Make sure that no segment has more than 32 devices
Check stub line usage
Ensure that the baud rate restrictions due to stub line usage are followed
Check that device addresses are correctly set on the device as shown in your drawings
Device power
If at all possible, fuse each device so it can be powered up/down separately
Ensure that the device has adequate power in all conditions, e.g., high current outputs all turned ON simultaneously
Power a device down prior to connecting or disconnecting the connector, especially at high baud rates
Commissioning and Maintenance
71
143

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Static Physical Layer Test

144
Check the physical layer with a physical layer test tool

Such tools can detect many types of wiring errors
Swapped wires
Broken wire
Short circuit lines A-B
Short circuit A/B-shield
Open in shield
Missing or excessive termination
Segment length
Reflections
Integrity of the physical layer is important
Physical layer problems complicate commissioning
Is device communicating?
Did it get set up incorrectly?
72
145

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
Run-Time Analysis
146
Run-time analysis tools connect to operational bus and perform

Determination of a “Live List” (All Active Stations On the Bus)
Analysis of protocol for PROFIBUS DP and PA Networks and Devices
Assists in finding startup problems
Collection of statistics for repeats, drop-outs, corrupted messages, etc.
Trigger Functions / Decoding / Logging
Vendors with PROFIBUS DP (RS485) tools
ProCentec
Softing
Indusol
73
Run-Time Analysis
147
Run-time analysis tools perform

Oscilloscope functions
Wave forms
Signal levels
Reflections
Network topology determinations
Assist in locating cabling errors, faulty devices, etc.
ProCentec/ Softing North

Grid Connect America

148

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
74
Diagnostic Information
149
PROFIBUS provides a wide variety of diagnostics

Vendors have the capability to build any type of error detection into the device and report it to the PLC/DCS
150
High-speed I/O - data exchange
Controller Device
75
151
High-speed I/O - data exchange and diagnostics
Device Indicates Diagnostics to Report
Controller Device
= Output Data = Input Data = Diagnostic Indicator
152
Diagnostic Request and Response (Up to 244 bytes)
Controller Device
= Diagnostic Request = Diagnostic Response
76
153
Back to Data Exchange (Up to 244 bytes)
Controller Device
154
Mandatory diagnostics – standard across vendors/devices

I/O Configuration Mismatch
Wrong Device at Address
Channel-Related (Standard)
 This Device has a Diagnostic
 This Module has a Diagnostic
 This Input/Output Channel
has a Diagnostic
 The Diagnostic is
 Wire Break
Device-Related (Vendor Specific)  Short Circuit
Identifier-Related (Standard)
 Missing Load Power  Undervoltage
 Module in this Slot has a
 Actuator Stuck  Overvoltage
Diagnostic
 ...  ...
77
155
Examples of diagnostic information

The Device Monitors the Output Channels
In Order to Discover a Wire Break (No Current Is Flowing Although the Output Is Set to ‘1’)
An Analog Input Has a Range of 0..10V

An Input Voltage of 12V Is Detected and Reported As Overvoltage
Diagnostic information is not only “PROFIBUS

related” but may also be used to report
application/process problems
156
Typically can choose what to detect and report during parameterization

Enable/disable wire break, etc.
78
157

works Layer
Bus Tester
Network Diagnostic
Configuration
• Choose the
Connectors
Devices
• Terminations
• Set Address
• Best Practice
158
Available diagnostic information can be

Used by the Application (PLC or PC)
Passed on for further processing
Can be stored and archived for analysis and history
Displayed by HMIs
79

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PROFIBUS Introduction

PROFIBUS & PROFINET International (PI)

International creator, maintainer, and promoter of open, industrial

Sensors & Actuators

PI= PROFIBUS & PROFINET International

North American Regional PI Association

Support in North America:

PICC PITC PITL

Phoenix Contact Software 

Engineering and documentation

PROFIBUS and PROFINET Timeline

1987 1990 1995 2000 2005 2009

ISO = International Standards Organization

1987 1990 1995 2000 2005 2009

PROFIBUS Key Application

Open, international standard (IEC 61158)

2 Data link layer

Open, international standard (IEC 61158)

SD LE LEr SDr DA SA FC DU.. FCS ED

P SOF SD LE LEr SDr DA SA FC DU.. CRC EOF

PA= Process Automation

PROFIBUS DP- Decentralized Periphery

Plan/Design Configuration Installation Commissioning Maintenance

• How • Configure • RS485 • Using a • Diagnostic

Controller - Device Concept

Passive Stations (Field Devices)

Passive Stations (Field Devices)

Cyclic and acyclic channel accesses

Cyclic Communication Cyclic/Acyclic Communication

I/O Cycle Time -

High-speed decentralized periphery (DP) I/O data exchange features

PROFIBUS DP and PA utilize the same protocol

On-demand access of device parameters

Plan/Design Configuration Installation Commissioning Maintenance

• How • Configure • RS485 • Using a • Diagnostic

Plan and Design DP Network

We need to start with learning some definitions

Segment and Network Lengths

What are the constraints on segment length?

Baud Rate (kbits/s) Max. Segment Length

What are the constraints on the number of devices?

Segment and Network Lengths

Network May Consist of

Segment and Network Lengths

Communication Path Lengths

PROFIBUS – DP segment and communication path length

8,000 Segment [m]

Baud Rate (kbits/s)

Total Repeaters In A Network

DP network segmentation example

Address #1 Address #31 Address #32 Address #61

No Address OLM: Fiber optic repeaters

Address #121 Address #92 Address #91 Address #62

PROFIBUS DP Communication Media

PROFIBUS Communication Media

Most commonly used physical layers will be covered in this class

Use of Stub Lines

What is a stub/spur/tee line?