Fieldbus introduction

Content

1. Introduction
2. Fieldbus general
2.1 Profibus PA
2.2 Foundation Fieldbus
3. Segment checker
4. Advanced diagnostic
 Conventional technique

4-20mA technique:
Factory
level Ethernet/TCP/IP Work Internet/Intranet
station
Bus
Cycle time Management PC/VME
< 1000 ms

Cell- Ethernet TCP/IP

level
PLC
Bus Operations Maintenance
Cycle time
< 100 ms

Ex
Field-
level
 Fieldbus technique

Factory
level
Ethernet/TCP/IP Work Internet/Intranet
Bus
Cycle time
station
Management PC/VME
< 1000 ms

Cell-
level Ethernet TCP/IP
Bus
Cycle time Operations Maintenance
< 100 ms PLC

Field-
level Fieldbus Fieldbus EX
Bus
Cycle time
< 10 ms
 Some advantages

Why fieldbus?
– Much easier wiring compared to conventional method
– Space saving
– Powerful field devices with more Information
– Preemptive maintenance
 Advantages cabling

Marshalling
and barrier
Control system

Junction box
 Advantage Space

Less wiring
– No marshalling Fieldbus
– Barrier in the field 992 devices

– More instuments per cable

Conventional
315 devices
 Advantage More Information

Intelligent field devices

– The more intelligent the more variables
each variable a 2-wire connection (fast) or
HART (slow, additional Hardware)

Fieldbus
192 Variables

Fieldbus
8 Variables

Fieldbus
Conventional: 3 Variables
Conventional: 3 Variables
1 Variable
 Advantage Maintenance

Maintenance:
– The field device sends an alarm and description if it has a
failure (currently only current rise)
– The field device sends a warning “Maintenance soon
required” (conventional not possible)

Predictive maintenance possible

 Fieldbus general

…all digital, serial, two way…

– all digital means you have the process value converted in the
field device and then transmitted like this:

1 1 0 …
 Fieldbus general

…all digital, serial, two way…

– serial means you have transmission telegrams one after the other like
this:
– two way gives you the ability for closed control loops on one bus

Field device 1 Field device 2

DCS
 Fieldbus for Process automation

For Process automation a fieldbus with the following

aspects is needed:
– Data and energy via same wire
– Intrinsic safety as an option

From the many busses defined in IEC61158-2 only two

remain:
– Profibus PA

– Foundation Fieldbus (FF)

 Fieldbus general

Profibus PA and FF have the same specification of the

physical layer as per IEC 61158-2:
– Transmission rate of 31.25 kBit/s
– Total cable distance of 1900 m maximum
– Maximum spur length 120 m
– Up to 32 devices per segment (Host + 31 field)
– Manchester II coding used to transmit data
– Minimum working voltage 9 Volts
– Average current consumption 20 mA per device
– Data transmission by a ± 9 mA modulation signal
 Fieldbus general

• Manchester II coding:
voltage modulation measured at 50Ohm
(measured between signal leads)
Bits: 1 0 1 1 0

Supply voltage + signal amplitude

Supply voltage

Supply voltage - signal amplitude

1 Bit t
 Fieldbus general

• Transmit level 0.75Vpp to 1Vpp @ 50 Ohm

• In case when transmitting signal is between
1Vpp and 2Vpp Î one or more terminators are
missing
• Recommended values for transmit level are as
follows:

Transmit level Transmit level

Wire condition
peak-to-peak peak
> 1V > 0.5V Missing terminator
0.7V … 1V 0.35V … 0.5V good
0.3V … 0.7V 0.15V … 0.35V e.g. 3 terminators
< 0.3V < 0.15V 3 or more terminators
Fieldbus wiring

Bulk
Power
Supply

Power
Supply /
Power
Conditioner

“Junction Box”
controller
 Power Supply / Power Conditioner

• Bulk power supply represents a very low impedance

– Much less than 50 Ohm
• If this impedance will be connected directly to a
fieldbus segment this will “short” the
communication signal
• To avoid this, a matching impedance is required
 Matching Impedance

• In principle there are two possibilities two build up

the matching impedance

Active design Passive design

+ fieldbus + fieldbus

- fieldbus - fieldbus
 Advantage of Passive Design

• No active components
– higher reliability
– Lower heat generation
• Symmetrical design
– Balance is an important value for the noise sensitivity of the
system
Why balanced design?

Noise Potential noise

source:
- bad wiring practices
Z/2 (AC cables close to
Z + fieldbus
bus cables)
- Corrosion (i.e. field
device flooded)

Balance reduces
the sensitivity
Z/2 against noise
- fieldbus
Conclusion of balance

• Each component of a fieldbus system has an impact to

the balance
– H1 controller
– Bulk Power Supply
– Fieldbus Power Supply/Power Conditioner
– Each field device
– Cable
• If one component is unbalanced the complete system
will be unbalanced
• This will increase the sensitivity to noise
• Increased sensitivity to noise
– will happen a decreased reliability (more bit errors)
– Can decrease the plant availability
 Balanced power supply

The Power Hub:

– Enclosed Motherboard
– Passive Power Conditioning
Simplex

– CREST Technology for safe operation even under fault

conditions
– Fault output via diagnostic module (Basic or Advanced)
– Redundant or non redundant board versions

Redundant
– Host connection via system cable available
– Segment protection against host spur faults
– High efficiency (85%)
– Fully galvanically isolated
– 30V / 500mA Output for maximum number of
field devices
Fieldbus wiring

Bulk
Power
Supply

Power
Supply /
Power
Conditioner

“Junction Box”
controller
 Cables

• Data from max. 32 participants is transmitted over a

pair of twisted shielded wires
• Shielding is required for EMC protection
• Due to “high” frequency signal, AC resistance
matters
Commonly used:
Type A cable: Shielded twisted pair
Resistance load per unit length 44 Ω/km
Characteristic Impedance 100 Ω
at f = 31.25 kHz
Wire cross section >=0.8 mm²
Capacitance per unit length 2 nF per km
 Cables

What happens if you use wrong cable?

Example:
noise
Does not reach
max. amplitude

Rise/fall time
is too high
 Cables

• Effect: (description of End User)

– The communication was stable for a long time, but than a
field device disappeared for several hours from live list.
– Then the device could be seen again.

• The main problem was, that an improper cable with a

too high capacitance was used
Fieldbus wiring

Bulk
Power
Supply

Power
Supply /
Power
Conditioner

“Junction Box”
controller
 Fieldbus distribution

Several ways to distribute are allowed:

– Daisy chain
 Fieldbus distribution

Several ways to distribute are allowed:

– Daisy chain
– T-connections
 Fieldbus distribution

Several ways to distribute are allowed:

– Daisy chain
– T-connections
– Chicken foot
 Profibus

• Master-slave principle
• Two kinds: DP and PA
– PLC normally have a DP Card so the conversion to PA must
be done in the field =Segment coupler
• Fast in terms of cycle time
– 32 participants with 8 byte each result in a cycle time <0.5s
• Control in Master
How does Profibus work?
Token ring between masters

Master – Slave - Principle

Master (Class 1) Master (Class 2)

Central control, cyclic Engineering tool for
PLC data exchange with parametrisation and
PROFIBUS devices commissioning of
devices

PROFIBUS

Devices (Slaves)
Analog or digital peripheric devices such as I/Os, drives,
transmitter, valves and terminals
 Connection between DP and PA

Normally DCS systems have a DP connection. How to

transform this into a PA Bus?

DCS/PLC

DP Bus
controller
PA Field device
 Connection between DP and PA

DCS/PLC

DP Bus
controller

PA Field device
 Connection between DP and PA

to DP-Master to Bulk Power Suppy

DP Slave Simulation

Diagnostic Module
Power Module

Power Module

Power Module

Power Module
Gateway

Data Buffer

PA PA PA PA
Master Master Master Master

Four PROFIBUS PA Segments

 Connection How does it work?
DP Slave replies
with WAIT until the
PA device responds

DP Slave Simulation
Gateway

DP / PA Bridge &
Data Buffer

PA PA PA PA
Master Master Master Master

Independent of DP Acyclic Data Exchange

Engineering Station Class 2:
Cyclic Data Exchange Parameters, Programming
DCS, Master Class 1:
Data Read and Write, Commands
 Connection DP and PA

• Each segment has a PA Master- short cycle time

• Totally transparent, no parameterization
• Diagnostic over Profibus
• Same power supplies as for FF
• Gateway redundancy and Flying redundancy
• Low heat dissipation 10..13W
 Foundation Fieldbus

• Publisher- Subscriber
• Currently H1 solution in practice,
faster HSE seldom used
• Slower if you use DCS control, fast if Control in the
field used. “Macrocycle timing”
• Truly deterministic
 How does FF work?

Arbitrator – Producer – Subscriber Principle

Host (PLC, Linking Device) Engineering

Engineering tool for

parametrisation and
commissioning of
devices

FF H1

LAS =
Link Active Scheduler
Devices can be in any device
Analog or digital peripheric devices such as I/Os, drives,
transmitter, valves and terminals
How does FF work?

LAS = Link Active Scheduler

Schedule, LAS = Link Active Scheduler
P = Publisher
Scanning Table P = Publisher
S = Subscriber
S = Subscriber
CD = Compel Data (request)
a CD = Compel Data (request)
LAS b
c Physical medium

CD(x,a)

Device x Device y Device z

a b c a d a
P S P S P S

LAS puts
Device
is arbitrator,
(x)request
has thatworks
for
value
value
through
-> (a)
Publisher
onto
schedule
the bus
How does FF work?

LAS = Link Active Scheduler

Schedule, LAS = Link Active Scheduler
P = Publisher
Scanning Table P = Publisher
S = Subscriber
S = Subscriber
DL = Data Link Packet
DL = Data Link Packet
LAS
Physical medium

DL(a)

Device x Device y Device z

a b c a d a
P S P S P S

Device (x)
Devices (y)+(z)
publishes
need that
valuevalue
(a) on
->the
Subscribers
bus
 How does FF work

• Macro cycle can look like this:

Published value

Internal execution
time
 Comparison FF and PA

Foundation Fieldbus Profibus PA

+ Deterministic + Fast
+ Control in the field + easily connectcable to a even
+ open standardized control faster fieldbus network for
blocks devices (DP)
+ same tool for control blocks as
for parameterization - no control in the field
- Sometimes different software
-slower if centralized control for parameterization

You achieve the same using different ways,

P+F supports you whichever path you choose
 System layout

• How to set up a topology

• What to do in hazardous areas
• What are problems and how to avoid them
 General purpose application

DCS

Field Devices from

Segment other vendors

P+F Field Devices

16..32V Bus terminator
(Valve coupler + TM-I)
Safe
area
230VAC
 Problems
Power supply failure, In case of a short circuit,
Bus topologies
My DCS bus controller
have three communication
limited Voltage typical problemsis down –
and Current and all devices are lost
Single
can have a failure failures could lead to bus breakdown

3
1 2

16..32V
Safe
area
230VAC
 Solution

As there are three problems, we need three solutions!

• Host Redundancy
• Reliable, redundant Power Supply
• Reliable Field Instrument Connection with Protection against
Instrument Failures
 From Top to Bottom...
…Pepperl+Fuchs

Power
Supplies

Segment
Cables Junction Boxes FieldBarrier Term.
Protectors

Surge
Protect.

Fieldbus
Field Devices

Field Devices
Field Devices

Field Devices
Process
Interfaces
High-Power Trunk for Zone2 and safe area
Achieves:
DCS • Longest cable run
• Highest no. of devices
Method:
• High energy on the Trunk
• Ex nL: Energy limitation at each Spur via
Segment Protector

Ex nA

Ex nL

Live working on
field devices permitted
Zone 2/Class I, Div 2 without gas clearance
 FieldConnex - Zone 2 and safe area
Short circuit protection
for each channel Accurate current
(with LED indication) limitation for each
channel (58mA)

Safe
A fault at one Zone2
area
instrument (e.g.
16..32V
short circuit) has
16..32V no impact on the
230VAC other outputs or on
the segment
230VAC
 Non-Incendive Fieldbus
Non-incendive
equipment
Associated Non- Voc
incendive Field Wiring
Power Apparatus Ioc
Supply Vout
La
Div.2 wiring method:
-PLTC or ITC cable/wire tray Ca
-Armored cable or conduit Segment
Protector

(General purpose
Lcable
Vmax ≥ Voc = Vout wiring) Non-incendive
field wiring Ccable
OK to do Live
Ca ≥ Ci + Ccable maintenance! Vmax
Devices
Field Li
La ≥ Li + Lcable
Non-incendive field
Ci
wiring apparatus
Zone 2
Class I/Div2
See also: NEC Article 500, ISA 12.12.01-20XX
 Differences between Ex nL and Ex nA

Ex nL Ex nA
(From 2007 onwards: Ex ic)
• Shock test mandatory
• Verification of the “intrinsic safety” • Apparatus considered only in normal
(U, I, L, C) condition
• Apparatus is considered only in – Does not cover lead breakage and
normal condition short circuit as “normal operation
– Ex nL is covering lead breakage and condition”
short circuit as “normal operation • Plugging under life condition forbidden
condition” • Increased safety (Ex e) electrical
• Plugging under life condition installation
• Climate test mandatory (very critical for
• Intrinsically safe installation encapsulated devices)
 Wiring practices

• For safe area and Zone 2, normal Fieldbus wiring shall be followed
however local regulations recommended

• For Zone 1, the wiring method has to be according to local regulations

where the main objective is to protect the wiring from mechanical
damage.

• Examples are conduit wiring is US and armored cable in Australasia.

• The wiring practices have to be checked with the local certification

bodies and the country regulations
 Difference between Ex nL and Ex i

Ex nL Ex i
• No fault condition consideration • Fault condition consideration
• No galvanic isolation – up to 2 faults for category 1
• Higher voltage and/or capacity possible apparatus
– no fault condition • Galvanic isolation preferred (for category
– safety factor 1.0 1 associated apparatus)
– IEC 60079-27 has integrated a safety • Reduced voltage and/or capacity (2 faults
factor of 1.1 depending on “US condition and safety factor 1.5)
requirements”
 Zone 2 Application without Energy Limitation

• The Segment Protectors are certified Ex II 3 G EEx nA[L] II T4

• You can connect field devices to the segment protector which are
allowed to be used in category 3 (zone 2) environment
– Independent of the protection type
– no live disconnect
 Zone 2 Application with Energy Limitation

• You are allowed to disconnect field devices if

– the field device is certified Ex II 3 G EEx nL II T* or better and
– you fit the electrical safety values (simplified proof of intrinsic
safety)
 Zone1 installations
• Basically there are three possibilities to install a fieldbus system within
zone 1 of a hazardous area:

• Non-IS(EEx d)
• Trunk and spurs must be installed in increased safety EEx e

– A full intrinsically safe fieldbus segment

• Intrinsic safe trunk and spur
• Requires the use of IS Power Repeaters/Power Link module

– A mixture of EEx e and EEx i

• Trunk has to be installed in increased
• Spurs are intrinsically safe
• Allows the use of Non IS Power Supplies/Power Repeaters/Power Links
 FieldConnex - Zone 1 (EEx d)
Fieldbus Segment Protector Ex me
Power Hub

Ex e

16..32V

230VAC 16..32V Instruments

Ex d

Zone 1
 Segment Protector R-SP-E12
• Each Non-IS field device, which is allowed to be used in Zone 1 could be
connected to this Segment Protector
– Typically this are EEx d field devices
• Technical values
– Input voltage 9 … 32 V DC
– Output voltage < 32 V DC
– Voltage drop < 1.3 V
– Output current per spur < 40mA
– Short circuit current < 50mA
– Fieldbus terminator integrated
• Activated if Jumper connected
• Deactivated if Jumper not available
 Features of R-SP-E12

• The Segment Protector is certified

Ex II 2 G EEx mbe IIC T4
– mb means encapsulated for use in zone 1
– Number of certificate: PTB 04 ATEX 2100X
• Special conditions
– Shall be mounted in an additional enclosure which meets the requirements
of EN 50014
– Segment Protector will be connected only via certified terminal clamps
– Temperature range -40°C … +70°C
– Additional enclosure is allowed to be opened in de-energised status only!
 Zone 1 Hazardous Area - IS

– A full intrinsically safe Fieldbus segment

• IS Barrier( Power supply) in the control room
• Shorter cable distance and less number of devices

– A mixture of EEx e and EEx i

• IS Barrier( Power supply) in the Field
• Longer cable distance and higher number of devices
 Zone 1 Hazardous Area - IS

– A full intrinsically safe Fieldbus segment

• Method1
• Entity concept:
– Intrinsic safe bus (trunk and spurs!)
– 70mA and ~11V
– Reduction in cable length because of low voltage

Realistically 3 field devices on one Segment, length depends on voltage

drop
– (1 device with 20mA makes a drop of 0.88V/km)
 Zone 1 Hazardous Area - IS

– A full intrinsically safe Fieldbus segment

• Method2
• FISCO concept
• Intrinsic safe trunk and spurs
– More power 100mA and 24V..32V depends on field device
– Cable 1000m, spurs 60m
– Easier proof of IS as inductances/capacitances are regarded in the
certificate
– Limits to one power supply, no true redundancy!
Realistically 5 field devices in one segment with all the design
considerations
 Zone 1 Hazardous Area - IS

• High Power Trunk or FieldBarrier concept

– Trunk is Ex e( increased safe) ad Spurs intrinsic safe

– Proof of IS either in FISCO or Entity
– Longest cable run possible 1900m overall and 120m Spur
– No limitation of voltage and current on trunk for Ex-I outputs
– Redundant power supplies
Hazardous area application with the least difficulties
 FieldConnex - Zone 1 and Zone 0 - IS
Or 3 FieldBarriers in one box

FieldBarrier
Fieldbus
Power Hub

Zone 1

Ex e

Ex ia
(FISCO + Entity)

16..32V

Zone 0/1
230VAC 16..32V
 FieldConnex - Zone 1 and Zone 0 - IS
Connecting many FieldBarriers to
A fault at one the same trunk is possible (daisy-
instrument (e.g. short chaining is an option), as 1A and
circuit) has no impact up to 32V are available on the
on the other outputs or trunk. This allows up to 31
on the segment instruments on the same trunk.

Zone 1

Ex e

Ex ia
(FISCO + Entity)

16..32V
Both FISCO and Entity
Zone 0/1 are supported
instruments
230VAC 16..32V at the same time, at the
same FieldBarrier,
supporting Ex ia IIC.
 Advantages

• Reduces the No. of required Fieldbus Power Supplies due to the High
Power in the field (EEx e / EEx i concept)
• Galvanic isolation in the field
– No potential equalization throughout the plant necessary
– No galvanic isolation in the Fieldbus Power Supply required Î
Power Conditioners could be used (reduced price)
• Short circuit protection of the outputs
• Output cable length 120m without fieldbus terminator
 Technical values FieldBarrier
• FieldBarrier will be connected to a
– Non-IS Power Supply or Power Repeater
– Power Hub with standard power supply
• FOUNDATION Fieldbus values Power Hub
– Output voltage > 28 VDC
– Output Current < 500 mA
• FOUNDATION Fieldbus values FieldBarrier
– Input voltage 16 ... 32 VDC
– Output voltage > 10 V at each channel
– Output current < 40 mA per channel
– Max. output cable length 120 m
 FISCO / ENTITY Concept
• FISCO/Entity vsforFieldConnex
Two different barriers IS
Entity and FISCO instruments
• Limited number of devices (typically 3-5) Zone 0/1
• Low-reliable power source solution (barrier not truly redundant)
• Short-circuit protection not feasable (problem: Ex parameters)
• Trunk and spur length limited
- max. 1000m total (trunk including spurs)
20..35V
230VAC
(Repeaters to extend the cable length can not be used)
- max. 60m spurs

High Power Trunk ConceptZone 1

• Supports FISCO and Entity instruments simultaneously

• High power for long cable length and more instruments
- 500mA for 32 devices Ex e
- supports higher voltage to enable longer cable lengths
- max. 1900m in total, 120m max. at eachEx output
ia
(Repeaters can be used to extend the cable
(FISCOlength
+ Entity)to max. 9.5km)
16..32V
• Redundant+Reliable power solution; optional Host Spur Protection
• Short circuit protection for each instrument
• Mix Safe16..32V
230VAC Area, Zone 2 (Ex n), Zone 1 (Ex d) and Zone 0 (Ex i, FISCO
Zone 0/1
and Entity) instruments on the same Trunk!
Based on
the interoperability study
and the FuRIOS study
performed by Infraserv Hoechst and Aventis Pharma
 Ex

HOST EEx e
H1-Bus Fieldbus Fieldbus
H1-
Card -barrier -barrier
Power
Conditioner EEx i

Field device 1 Field device 5

Field device 2 Field device 6

Field device 3 Field device 7

Field device 4 Field device 8

 FuRIOS - technical results

Topology solution:
• Hazardous area Zone 1 → preferred protection method is Ex i →
barrier required
• Ex e / Ex i combination required → barrier is in the field
• High reliability of the fieldbus network needs to be realized even under
the other requirements of
- more power in the field and
- more instruments connected
• Multiple field-integrated barriers with multiple protection against
instrument failures required

Source: Publication in atp 44 (2002) Issue 12

 FieldConnex Total Solution

Segment Protector
FieldBarrier

Ex e

Zone 0
Ex n /
16..32V FNICO

Ex d
Ex ia
(FISCO and
230VAC Entity)
Zone 2 Zone 1 Zone 0
FieldConnex = Scalable Fieldbus Solutions

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