Industrial Data Communication

IDC317B: Unit 5
Fieldbus Network

Faculty of Engineering and Built Environment

Industrial Data Communication
IDC317B
 Foundation Fieldbus

2020 IDC317B Notes 2

 Foundation Fieldbus
• Fieldbus is a Local Area Network for process
control that uses shared wiring for powering
devices and carrying signals between devices.
• Foundation Fieldbus consists of four layers.
Three of them correspond to OSI layers 1, 2,
and 7. The fourth is the so-called ‘user layer’
that sits on top of layer 7 and is often said to
represent OSI ‘layer 8’, although the OSI model
does not include such a layer. The user layer
provides a standardized interface between the
application software and the actual field
devices.
• The concept behind Foundation Fieldbus is to
preserve the desirable features of the present
4–20 mA standard (such as a standardized
interface to the communications link, bus
power derived from the link and intrinsic safety
options).

2020 IDC317B Notes 3

 Fieldbus Operation
• A number of devices share the same Fieldbus wires. Fieldbus devices
vary the voltage on the two wires to send the digital signals. Fieldbus
also uses two wires to carry power to the devices.
• Because devices share the wires, the devices can send data to each
other without a host controller.
• Fieldbus data transmissions have more information than just a single
variable about temperature, pressure, or valve position.
• From the data that are shared between the devices, the devices can
determine how to control the process.
• The host device only supervises the operation.
2020 IDC317B Notes 4
 Fieldbus

Fieldbus

• The two wires are a twisted pair similar to the usual 4-20 mA wiring
used for conventional devices.

Fieldbus wiring diagram

2020 IDC317B Notes 5

 Foundation Fieldbus Configuration
• Fieldbus is a process control local area network used for interconnecting
sensors, actuators, and control devices. Two terminators are required. A
power supply and a power conditioner are needed to provide Fieldbus power.
• A common type of Foundation Fieldbus configuration is shown below.

2020 IDC317B Notes 6

 Fieldbus Configuration
• A twisted-pair trunk cable connects control room equipment with a number of devices in
the field, for example, sensors such a temperature or pressure transducers and actuators
such as valve positioners.

• The field devices can be connected with spur or drop cables to a common terminal block,
called the chickenfoot, in a junction box. Devices can also be connected along the trunk
cable with spurs.

• A terminator (T) is required at each end of the Fieldbus cable to avoid signal distortion and
allow the twisted-pair cable to carry digital signals.

• Power to the devices is provided by a power supply through a power conditioner (PC). The
power conditioner is needed to separate a conventional power supply from the Fieldbus
wiring so that the signals are not absorbed by the power supply.

2020 IDC317B Notes 7

 Fieldbus: Implementations
• Two types: FF H1 and HSE (High-speed Ethernet)
• The two types use different physical media and communication speeds

Foundation fieldbus H1 (1996):

• Most common F. Fieldbus
•

• Operates at 31.25 kbps

• Generally connect host and field devices.

• Uses stranded twisted pair wiring in both conventional and intrinsic safety
applications.

2020 IDC317B Notes 8

 Fieldbus: Implementations
HSE(High Speed Ethernet-1999):
• Operates at 100/ 1000 Mbps

• Generally connects IO subsystems, host systems, linking devices and gateways.

• Does not provide power over the cable. Proposed use of the IEEE802.3a standard
(Power over Ethernet (PoE) standards)

2020 IDC317B Notes 9

 Fieldbus
• Hierarchy structure showing H1 and H2 levels

2020 IDC317B Notes 10

 Fieldbus
• H1(field) Fieldbus is a bidirectional
communication protocol used for
control applications such as
temperature, level and flow. Provides
low speed (31.25 kbps) and error
proof transmission.

• H2(Cell) Fieldbus is used in advanced

processes, remote input/output and
high-speed factory automation
application. Operates at high speeds
of 1 mbps or 2.5mbps.

2020 IDC317B Notes 11

 Fieldbus- Transmission models
• Two methods a device on a network can transmit and receive information:
• Source/destination
• Publisher/ subscriber

• Source/ destination: point to point communication strategy applicable to both

master/slave polling and peer-to-peer networking.

• The data packets have unique source and destination.

• Multiple packets deliver the same message to multiple devices, which results in
wasted bandwidth.

• Each transmission block: identifies sender and recipient, includes a checksum (CRC)
to verify that data arrived correctly.

2020 IDC317B Notes 12

 Fieldbus- Publisher/ Subscriber model
• Foundation bus uses a combination of token passing and publisher/ subscriber
model.

• Messages are identified by their content rather than their address. If a node needs
data it will accept that identifier and consume it.

• Since data is identifies by its content, multiple devices can consume the same data at
the same time from a single producer. This results in considerable reduction in traffic
time.

Fig: Simple network illustrating network models

2020 IDC317B Notes 13
 Fieldbus- Source/ destination model
• E.g. of full sequence of transactions using source/destination:

• Seven transactions

2020 IDC317B Notes 14

 Fieldbus- Publisher/ Subscriber model
• E.g. of full sequence of transactions using publisher/ subscriber:

• In contrast to the 7 transactions in source/destination only 3 transaction. Reducing

traffic.

2020 IDC317B Notes 15

 Fieldbus- LAS
• Main factor in FF is to provide peer-to-peer communication between field devices.

• This enables each device on the bus to exchange data with other devices on the bus
directly, without having to route the signals through the control system first.

• In order to achieve peer-to-peer communication, access to the fieldbus is managed

through a deterministic centralised bus schedular called link active schedular (LAS).

2020 IDC317B Notes 16

 Fieldbus- LAS
• Multiple link layers are incorporated to provide redundancy. In the event of failure
of the primary link master, the integrity of the system is ensured by the second link
master.

• LAS caters for both cyclic and acyclic data transmission.

• Process data requires cyclic, scheduled-to-data transfers between devices on the

fieldbus. (deals with critical information).

• Non-cyclic data (Periodic bus audit or initiating of newly connected devices ) is less
important and should have no effect on the collection and distribution of process
information.

2020 IDC317B Notes 17

 Fieldbus- LAS
• LAS accomplishes both cyclic and acyclic scheduling. It contains a list of activities
that are scheduled to occur on a cyclic basis.
•

• At the scheduled time, LAS sends a compel data (CD) message to a specific data
buffer in a fieldbus device. The device than immediately broadcasts or publishes a
message to all devices on the fieldbus.

2020 IDC317B Notes 18

 Fieldbus- LAS
• In between the cyclic transmission of scheduled message, devices are able to send
unscheduled (acyclic) messages. This is achieved by using free-running pass token
(PT) that allows each device to publish any information it might have whilst it holds
the token.

• When the devices receives the PT, the message on the queue is transmitted on the
bus. Message may be sent to single destination or multiple.

2020 IDC317B Notes 19

 Fieldbus- LAS
• Algorithm used by LAS

• The LAS periodically sends a probe node (PN) message to the addresses not in the
live list. If the device is present and receives the PN, it immediately returns a probe
response (PR) message. A time distribution (TD) command ensures that all devices
have exactly the same time, which is synchronised through the system.

2020 IDC317B Notes 20

 Fieldbus- Function Blocks
• FF makes use of function blocks to represent various application functions. Allowing
distributed control to be implemented. []

• 10 sets of standard function blocks used for basic control

2020 IDC317B Notes 21

 Fieldbus- Function Blocks
• Additional function blocks used for advanced control:

2020 IDC317B Notes 22

 Fieldbus- Function Blocks
• E.g. of control strategies:

• Function blocks reduce bus traffic, and frees host (DCS or PLC) from having to make
every decision allowing it to focus on higher level functions.
• Function blocks can be built into fieldbus devices to achieve the desired
functionality.
2020 IDC317B Notes 23
 Fieldbus- User Application Blocks
• Complete control loop:

• Other application blocks include: Resource block, Transducer block, Functional

block scheduling

2020 IDC317B Notes 24

 Fieldbus- Topology
• Transmission based on the IEC 61158-2 standards
• Manchester Bi-phase L encoded synchronous transmission running on Shielded twisted-pair
cable.

• Data rate: 31.25 Kbits/s.

• 32 station per line segment.

• Max distance 1 900 m. (can extend to 10 Km and, through the use of four repeater
max of 126 station )

2020 IDC317B Notes 25

 Fieldbus- Topology
• Standard practices is centred around four basic layouts:
• Non-bus powered network: 2-32 devices
• Bus powered network: 2-12 devices
• Bus powered IS network: 2-6 devices
• Low power bus-powered IS network: 2 + devices

• Possible structure:
• Tree
• Line
• Daisy-chain
• Point-to-point

2020 IDC317B Notes 26

 Fieldbus- Signals
• Devices signal each other by varying the current they draw from the network. The
signal is Manchester coded.

• The twisted pair cables, terminators, and the power conditioner work together as a
wiring system that can carry signals between Fieldbus devices. When a device is
enabled to signal (arbitrated by LAS), it varies the amount of current it draws from
the network.
• When not transmitting, a device draws power from the cable for its internal operation.
It also draws an additional 10 mA that it "wastes."
• When the device transmits a high signal, it turns off this extra 10 mA. This increases
the voltage between the wires.
• When the device transmits a low signal, it draws an extra 10 mA from the wires,
resulting in a voltage decrease.

2020 IDC317B Notes 27

 Fieldbus- Signals

• The signal waveform is shown above. Note that the signal is above and below
the24-volt non-transmitting level on the network.
• Digital data is sent on the Fieldbus at a rate of 31.25 kbits/second. Thus, each bit
cell is 32 microseconds long.

• The digital data, ones and zeros, is represented as a Manchester code. A zero is a
positive signal transition at the centre of a bit; a one is a negative transition in the
middle of a bit.

2020 IDC317B Notes 28

 Fieldbus- Signals

Manchester Code signal

• When a device begins transmitting, it puts out a preamble, an 8-bit sequence with
alternating ones and zeros. This pattern is used by the receiving devices to
synchronize themselves to bit cell boundaries.

2020 IDC317B Notes 29

 Fieldbus- Signals
• There are also two non-data symbols. N+, a high level during the whole bit cell, and
N-, a low level during the whole bit cell.

• These symbols are used to make an 8-bit start delimiter that shows where real data
starts and an 8-bit end delimiter that shows where data transmission stops.

2020 IDC317B Notes 30

 Fieldbus- Signals

• Fieldbus frame

2020 IDC317B Notes 31

 Fieldbus- Cable
• FF uses a twisted-pair cable, rather than a pair of parallel wires, to reduce external
noise from getting onto the wires. A shield over the twisted-pair further reduces
noise.

• For new installations or to get maximum performance from Fieldbus, the cable
should have the following characteristics:

2020 IDC317B Notes 32

 Fieldbus- Cable
• The low-speed (H1) bus is intended to utilize existing plant wiring and uses #22
AWG type-B wiring (shielded twisted pair) for segments up to 1200 m (3936 ft) and
#18 AWG type-A wiring (shielded twisted pair) up to 1900 m (6232 ft).

• Two additional types of cabling are specified and are referred to as type C (multi-
pair twisted without shield) and type D (multi-core, no shield).

• * AWG American wire gauge

2020 IDC317B Notes 33

 Fieldbus- Terminator
• Two terminators are required on each Fieldbus network segment. Generally, one
terminator is at the control room end of the cable and the other terminator is in
the junction box in the field.

• The terminator can be a separate part or may be part of a wiring block or part of a
Fieldbus power supply. The terminator should be clearly marked so that it can be
identified in an installed system.

2020 IDC317B Notes 34

 Fieldbus- Power
• An ordinary constant voltage power supply cannot be used directly to power a
Fieldbus. A power conditioner (PC) needs to be used to provide a filter between the
network and the power source so that the signals on the network do not get
absorbed by the power source.

• The voltage requirement need is between 9 and 32 Volts.

• A typical Fieldbus device uses about 20 mA of current. Generally, the number of

devices on a Fieldbus network segment is less than 16. A power supply with a 16 x
20 = 320 mA current rating is sufficient for most applications.

2020 IDC317B Notes 35

 Fieldbus- Limitation
Power distribution
• The number of devices that can be on a Fieldbus segment is limited by the power
supply voltage, the resistance of the cable, and the amount of current drawn by
the devices.

• The following example shows how to calculate the maximum number of devices
that can be attached at the chickenfoot:

• The Fieldbus power supply output is 20 Volts to the network.

• The cable used is 18 gauge and has a resistance of 22 Ohms/km for each
conductor.
• The trunk cable is 1 km long. The combined resistance of both wires is 44
Ohms.
• Each device at the chickenfoot draws 20 mA.
2020 IDC317B Notes 36
 Fieldbus- Limitation
• Since the minimum voltage needed by a device is 9 Volts, there are:
20 - 9 = 11 Volts, available to be used by the cable resistance.
• The total current that can be supplied at the chickenfoot is:
Voltage ÷ Resistance = Current available
11𝑉
= 250 mA
44 Ω/𝐾𝑚
• Since each device draws 20 mA, the maximum number of devices at the
chickenfoot of this example is:
Current available ÷ Device draw = Number of devices
250 mA ÷ 20 mA = 12 devices

2020 IDC317B Notes 37

 Fieldbus- Limitation
Attenuation
• As signals travel on a Fieldbus cable, they are attenuated, that is, they are reduced
in amplitude. The longer the cable, the greater the attenuation.

• The Fieldbus standard requires that a Fieldbus device transmits a signal at least
0.75 Volts peak-to-peak and that a receiver must be able to detect a signal of as
little as 0.15 Volts peak-to-peak. (14dB)

• If standard Fieldbus cable is used (attenuation of 3 dB/ km), then the cable can be
14 dB ÷ 3 dB/km = 4.6 km long.

• However, additional attenuation caused by spur cables that branch off the trunk
cable needs to be considered.
• This attenuation is largely caused by cable capacitance.

2020 IDC317B Notes 38

 Fieldbus- Limitation
Attenuation
• Standard Fieldbus cable capacitance is about 0.15 nF/meter and the attenuation
caused by capacitance is about 0.035 dB/nF.
• As an example, if the lengths of all the spurs is 500 meters, then the attenuation
will be:
500 m x 0.15 nF/m x 0.035 dB/nF = 2.6 dB.
• As an example, assume that the trunk cable is 800 meters long. The trunk
attenuation is:
3 dB/ km x 0.8 km = 2.4 dB.
• The total signal attenuation is 2.6 dB + 2.4 dB = 5 dB.

• This is well within the 14 dB available.

2020 IDC317B Notes 39

 Profibus

2020 IDC317B Notes 40

 Profibus
• Profibus (Process field bus) is a widely accepted international networking standard,
commonly found in process control and in large assembly and material handling
machines.

• It is an outcome of a joint project started in 1987 by Siemens and supported by

Bosch and Klockner-Muller

• Profibus is an open, vendor-independent standard that adheres to the OSI model

and ensures that devices from a variety of different vendors can communicate
together easily and effectively.
• Profibus supports single-cable wiring of multi-input sensor blocks, pneumatic
valves, complex intelligent devices, smaller sub-networks (such as AS-i), and
operator interfaces.

2020 IDC317B Notes 41

 Profibus

• It was designed for transparent networking at both the field and

cell levels of the production process; with lower level interface to
AS-i bus and upper level to Ethernet over Profinet.

• The bus interfacing hardware is implemented on ASIC (application 1 µF

specific integrated circuit) chips produced by multiple vendors, and
is based on the RS-485 standard as well as the European EN50170
Electrical specification. 100 Ω

• The terminator used in Profibus has a capacitor in series with the

resistor to block the DC power voltage.
Profibus field
terminator

2020 IDC317B Notes 42

 Profibus Specifications
• Master/ slave.

• Uses nine-pin D-type connectors (impedance terminated) or 12 mm quick

disconnect connectors.

• Max 127 nodes.

• Distance of up to 24 km (with repeaters and fiber-optic transmission).

• Data rates varying from 9600 bps to 12 Mbps.

• The message size can be up to 244 bytes of data per node per message (12 bytes of
overhead for a maximum message length of 256 bytes).

• Medium access control mechanisms are polling and token passing.

2020 IDC317B Notes 43
 Profibus Versions
Common version of Profibus:

• Profibus DP (distributed peripherals)- (master/slave).

• Profibus FMS (fieldbus message specification)- (multi-master/peer-to-peer).
• Profibus PA (process automation)- (intrinsically safe).

2020 IDC317B Notes 44

Profibus DP (distributed or decentralised peripheral)

• Profibus DP is designed for high-speed data transfer at the field level (as opposed
to Profibus FMS which tends to focus on the higher automation levels) and is based
around DIN 19 245 parts 1 and 2 since 1993.

• This means, automation controllers(PLCs, PCs, DCSs) can communicate with

distributed field devices such as I/O system( such as drives, valves, transducers,
analysers) over a fast serial communication.

• Profibus DP allows the use of multiple master devices. Each slave device is
assigned to one master. Thus, multiple masters can read inputs from the device but
only one master can write outputs to that device.

• Profibus DP is available in three (3) functionally graded versions: DP-VO, DP-V1, DP-
V2 designed for special demands of specific application areas.

2020 IDC317B Notes 45

Profibus DP (distributed or decentralised peripheral)

• Profibus is suitable as a replacement for the costly wiring of 24 V and 4–20 mA

measurement signals.

• The data exchange for Profibus DP is generally cyclic in nature. The central
controller, which acts as the master, reads the input data from the slave and sends
the output data back to the slave. The bus cycle time is much shorter than the
program cycle time of the controller (less than 10 ms).
• Specification:
• Data rates from 9 600 bits to 12 Mbits/s.
• Over wide range of media including cooper(RS485 and RS485-IS), plastic or glass fibre.
• Upto 15 km distance.
• The bus cycle time is much shorter than the program cycle time of the controller (less than 10
ms).

2020 IDC317B Notes 46

Profibus DP (distributed or decentralised peripheral)

• The RS485 (EIA 485) makes use if a twisted- pair shielded cable
(Type A) with the following characteristics:
Impedance: 135 to 165 Ω
Capacitance: < 20 pF/m
Loop resistance 110 Ω/km
Wire diameter: 0.64 mm

• The cable terminator in Profibus DP is integrated in the RS485

repeaters, bus terminals, and bus connectors and is active by a
built-in switch.

• Due to an active cable terminator required, it must be supplied

with power.

2020 IDC317B Notes 47

 Profibus FMS
• Profibus FMS (fieldbus message specification) is a peer-to-peer messaging format,
which allows masters to communicate with one another.

• Just as in Profibus DP, up to 126 nodes are available and all can be masters if
desired. FMS messages consume more overhead than DP messages.

• ‘COMBI mode’ is when FMS and DP are used simultaneously in the same network,
and some devices (such as Synergetic DP/FMS masters) support this. This is most
commonly used in situations where a PLC is being used in conjunction with a PC,
and the primary master communicates with the secondary master via FMS. DP
messages are sent via the same network to I/O devices.

2020 IDC317B Notes 48

 Profibus PA
• The Profibus PA protocol is the same as the latest Profibus DP with V1 diagnostic
extensions, except that voltage and current levels are reduced to meet the
requirements of intrinsic safety (class I division II) for the process industry.
• Profibus PA makes use of MBP-IS technology for electrical signalling. This allows
it to cater for both intrinsic safety and bus powered stations using two-wire
technology.

• MBP-IS- Manchester encoded, Bus Powered, Intrinsic Safety.

• Many DP/FMS master cards support Profibus PA, but barriers are required to
convert between DP and PA. PA devices are normally powered by the network
at intrinsically safe voltage and current levels, utilizing the transmission
technique specified in IEC 61158-2 (which Foundation Fieldbus H1 uses as well).

2020 IDC317B Notes 49

 Profibus protocol stack [1]

2020 IDC317B Notes 50

 HART

2020 IDC317B Notes 51

 HART Protocol
• HART- Highway Addressable Remote Transducer.

• The HART protocol was originally developed by Rosemount and is regarded as an

open standard, i.e. available to all manufacturers.

• HART uses the 40-20 mA standard interface and modulates digital data over it.

• HART main advantage is that it enables an instrumentation engineer to keep the

existing 4–20 mA instrumentation cabling and to use, simultaneously, the same
wires to carry digital information superimposed on the analogue signal.

• HART is a hybrid analogue and digital protocol, as opposed to most fieldbus

systems, which are purely digital.

2020 IDC317B Notes 52

 HART Protocol
• The HART communication operates in a way
that logic 1 applied to the input produces a
1200 Hz periodic signal while a logic 0
produces a 2 200Hz.
• The HART protocol uses the frequency shift
keying (FSK) modulation technique based on
the Bell 202 telephone communications
standard.
• Thus, when switching from logic 1 to 0, the
frequency changes from 1 200 Hz - 2 200Hz
with no discontinuity in the output.

2020 IDC317B Notes 53

 HART
• HART is based in a master/ slave communication
format that allows two masters to be connected
to each HART loop. The primary master may be a
DCS, PLC or PC whilst the secondary master can
be a handheld communicator or another PC.

• The HART protocol can be used in three ways:

• In conjunction with the 4–20 mA current signal in
point-to-point mode
• In conjunction with other field devices in multi-drop Master/ slave communication format
mode with primary and secondary master [2]
• In point-to-point mode with only one field device
broadcasting in burst mode.

2020 IDC317B Notes 54

 HART
• The HART protocol is implemented with the OSI model using layers 1, 2, and 7.

OSI Layer HART

7. Application HART Commands
6. Presentation
5. Session
4. Transport
3. Network
2. Dara Link Protocol Rules
1. Physical Bell 202

2020 IDC317B Notes 55

 HART- Physical layer
The physical layer of the HART protocol is based on two methods of communication:
1. Analog 4–20 mA:
• Used by the sensor to transmit an analogue value to the HART PLC or HART card
in a PC system. The sensor outputs a current value between 4 and 20 mA that
represents the analogue value of the sensor.
• Allows point to point communication.

2020 IDC317B Notes 56

 HART- Physical layer
2. Digital frequency shift keying (FSK):
• Based in the Bell 202 communication standard.
• Category 5 shielded, twisted-pair wire is recommended by most manufacturers.
• Devices can be powered by the bus or individually. If the bus powers the devices, only
15 devices can be connected. As the average DC current of an ac frequency is zero, it
is possible to place a 1200 or 2200 Hz ton on top of a 4–20 mA signal.
• The HART protocol does this to allow simultaneous communications on a multi-drop
system.

2020 IDC317B Notes 57

 HART- Physical layer

Example of HART handheld connection method [1]

2020 IDC317B Notes 58

 HART – Data link layer
• The HART protocol has two formats for digital transmission of data:
• Poll/response mode: the master polls each of the smart devices on the highway
and requests the relevant information.
• Burst (or broadcast) mode: the field device continuously transmits process data
without the need for the host to send request messages. This mode is fairly fast
(up to 3.7 times/s). it cannot be used in multi-drop networks.

2020 IDC317B Notes 59

 HART- Data-link layer

Preamble Start Address Command Byte Count Status Data Parity

Delimiter (AD) (CD) (BC)
(SD)
5 -20 bytes 1 byte 5 bytes 1 byte 1 byte 0- master 0 – 253 bytes 1 byte
1- slaves

HART Frame Format

2020 IDC317B Notes 60

 HART- Application Layer
• The application layer allows the host device to obtain and interpret field device
data. There are three classes of commands:
• Universal commands: used by all devices and provide access to information
used in normal operations.
• Common practice commands: Provide functions that are implemented by most
HART communication devices.
• Device-specific commands: are unique to each field device type and access set-
up, calibration information and construction information of the field device.

2020 IDC317B Notes 61

 HART- Application Layer
Some of HART commands
Universal commands Common practice commands Instrument specific commands

Read manufacturer and device type Read selection of up to four Read or write low flow cut-off
dynamic variables value
Read primary variable (PV) and units Write damping time constant Start, stop or clear totalizer
Read current output and percent of range Write device range Read or write density
calibration factor
Read up to four predefined dynamic variables Calibrate (set zero, set span) Choose PV (mass flow or
density)
Read or write 8-character tag, 16-character Set fixed output current Read or write materials or
descriptor, date construction information
Read or write 32-character message Perform self-test Trim sensor calibration.
Read device range, units and damping time constant Perform master reset

Read or write final assembly number Trim PV zero

Write polling address. Write PV units

2020 IDC317B Notes 62

 HART

HART Application Layer Implementation [1]

2020 IDC317B Notes 63

 HART Multiplexing
• Multiplexing can be used in applications that require interfacing with large number
of HART devices. E.g.:

2020 IDC317B Notes 64

 HART benefits
• Simultaneous analogue and digital communications
• Allows other analogue devices on the highway
• Allows multiple masters to control same smart instrument
• Multiple smart devices on the same highway
• Long distance communications over telephone lines
• Two alternative transmission modes
• Flexible messaging structure for new features
• Up to 256 process variables in any smart field device.

2020 IDC317B Notes 65

Reference
• Steve Mackay, Edwin Wright, Deon Reynders and John Park. Practical Industrial Data Networks: Design, Installation and
Troubleshooting. All with IDC Technologies, Perth, Australia First published 2004, IDC Technologies.
• Mick Crabtree. Industrial Communication Handbook. Jenny Warkwick, Crown Publications cc. 2008. 3rd Edition.
• Process Software and Digital Networks. INSTRUMENT ENGINEERS’ HANDBOOK. Third Edition, 2002 by Béla Lipták
• Schneider Electric Presentation: Industrial networks. Needs and available components. Technologies. Schneider Electric
policy

2020 IDC317B Notes 66

Industrial Data Communication

IDC317B: Unit 5
Fieldbus Network
 MODBUS

2020 IDC317B Notes 68

 Modbus
• Modbus is a serial communication protocol for two or more devices
connected to the same network. Designed by Modicon in the 1970s. Open
source code.
• It is a half-duplex, Master/ Slave system designed to connect a single master
to up to 247 slave devices.
• Modbus is an application layer (OSI layer 7) messaging protocol
• The messaging structure describes how a controller:
• Requests access to a slave devices
• Responds to a request from other devices in the bus network
• Detects and reports errors

• Commonly used in SCADA systems (Automation Industry)

2020 IDC317B Notes 69
 Modbus- Transmission Modes
There are three Modbus protocol transmission modes:
• ASCII
• Each byte in a massage is sent as two ASCII characters. It allows time intervals of up to
one second to occur between character without causing an error.
• RTU- Remote Terminal Unit:
• Uses binary coding and CRC
• Each byte in a message is sent as two 4-bit hexadecimal characters.
• Communication using RS232, RS 485, RS422
• All devices on the Modbus network must use the same baud rate as the master.

• The RTU mode achieves higher throughput than ASCII mode.

• Devices using Modbus ASCII and Modbus RTU are not compatible.

2020 IDC317B Notes 70

 Modbus- Transmission Modes
• TCP/ IP (Client/server)
• Uses regular Ethernet cables and switches to communication.
• Uses port 502 for TCP/IP communication
• Main difference with the other version is that it uses MBAP(Modbus Application
Header).
• MBAP is added to the start of each message.
• The MBAP contains all identifying information to route the data to address the device

MBAP Function Field Data Field

2020 IDC317B Notes 71

 Modbus- Transmission Modes
• Modbus serial messages can also be sent as Modbus RTU messages encapsulated
inside an Ethernet TC/IP packet.

• Encapsulated messages use Port 2000

• MBAP messaging and Encapsulated messages are not compatible.

• Apart from the fact that each byte in a message is sent as two ASCII characters, the
ASCII transmission mode differs from the RTU transmission mode in that the error
check characters are the result of a longitudinal redundancy check (LRC) calculation
that is performed on a the message contents.

2020 IDC317B Notes 72

 Modbus Transactions
• There are two types of types of transactions modes:
• Query response: only a single slave device is addressed.
• Broadcast: all slave devices are addressed and no response is required.

• In an error-free scenario, the exchange of information between client and

server can be illustrated as follows:
• The client (on the master device) initiates a request. The Modbus messaging protocol
(layer 7), generates a protocol data unit (PDU) consisting of a function code and a data
request.
• At layer 2, this PDU is converted to an application data unit (ADU) by the addition of
some bus or network related fields, such as a slave address and a checksum for error
detection purposes
• The server (on the slave device) then performs the required action and initiates a
response.

2020 IDC317B Notes 73

 Modbus-Parity Checking
• Since the Modbus protocol is a messaging structure (layer 7) it is
independent of the type of network over which it communicates.

• Assistance at the lower layers, in order to get the message across, may be
achieved using:
• RS-232, RS-485 or Bell 202 type modem links
• MODBUS+ (half-duplex over RS-485), or MAP.
• TCP/IP and Ethernet. The TCP/IP approach enables client/server interaction over
routed networks, although at the cost of additional overheads (processing time,
headers, etc.). An additional sub-layer is required to map the MODBUS application
layer on to TCP. The function of this sub-layer is to encapsulate the MODBUS PDU so
that it can be transported as a packet of data by TCP/IP
• As Modbus is typically used in a multidrop configuration the RS485 is
frequently used.
2020 IDC317B Notes 74
 Modbus-Frame Format

• Address field: In request frames, this byte identifies the controller to which the request is being
directed. The resulting response frame begins with the address of the responding device. Each slave
can have an address field between 1 and 247
• Function field: In a host request, this byte identifies the function that the target PLC is to perform.
In response frame, the response will echo that of the original request if the host (PLC) is able to
perform the requested function. Otherwise, the function field of the request will be echoed with its
most significant bit set to one, thus signalling an exception response.
• Data field: In a host request, this field contains information the PLC may need to complete the
requested function. In a PLC response, this field contains any data requested by that host.
• Error Check field: The numeric value of this field is calculated by performing a cyclic redundancy
check (CRC-16) on the message frame. This error checking assures that devices do not react to
messages that may have been damaged during transmission.

2020 IDC317B Notes 75

 Modbus-Parity Checking
• Modbus enables configurations for even or odd Parity checking, OR No
Parity.
• When using parity, the system counts the number of 1 bits to be transmitted
in the data portion of each eight-bit character, and the parity bit is then set
to a 0 or 1 to result in Even or Odd total of 1 bits.
• The parity bit is applied to the frame of each character as it is transmitted. At
the receiving device, the number of 1s is counted an dan error is set if they
are not the same.
• Parity checking can normally only detect an error if an odd number of bits
are dropped or acquired during transmission.
• If no parity checking is used, an additional stop bit is transmitted to fill out
the character frame.
2020 IDC317B Notes 76
 Modbus- CRC Checking
• The error checking field makes use of a 16-bit CRC, based on the CRC-16
polynomial (x15 + x14 + x2 + 1), which checks the contents of the entire
message.
• When compared with parity checking, a 16 CRC has been shown to provide
100% error checking for single-bit, double-bit, odd bit, and burst errors
shorter than 16 bits.
• The figure is 99.9969% for burst errors of exactly 16 bits and 99,9984% for all
other burst errors.

2020 IDC317B Notes 77

 AS-Interface BUS

2020 IDC317B Notes 78

 AS-Interface bus
• The AS-Interface (Actuator Sensor Interface) bus is a bit oriented communications
link, designed to connect binary sensors and actuators using bit-length messages.

• AS-i is especially suitable for lower levels of plant automation where simple (often
binary) field devices such as switches need to interoperate in a standalone local
area automation network controlled by PLC or PC.

• It was developed by 11 manufacturers: IFM Electronics, Pepperl + Fuchs, Allen-

Bradley, Banner Engineering, Datalogic Products, Siemens, Telemecanique, Turck,
Omron, Eaton and Festo.

• An open system network.

• Design of AS-I involves modular components. Connection to the network is made

with unique connecting modules that require minimal, or in some cases no, tools
and provide rapid, positive device attachment to the AS-i flat cable.
2020 IDC317B Notes 79
 AS-I bus- Physical Layer
• AS-i uses a two-wire untwisted, unshielded cable that serves as both
communication link and power supply for up to thirty-one slaves.
• A single master module controls communication over the AS-i network, which can
be connected in bus, ring, or tree topologies.

2020 IDC317B Notes 80

 AS-I bus- Physical Layer
• The AS-i flat cable has a unique cross section that permits only properly polarized
connections when making field connections to the modules.
• Alternatively, ordinary 2 wire cable (#16 AWG, 1.5 mm) can be used. A special
shielded cable is also available for high noise environments.
• Each slave is permitted to draw a maximum of 65 mA from the 30 V DC-power
supply. If devices require more than this, separate supplies must be provided for
each device.
• A total limit of 2 A has been establishes to prevent excessive voltage drop over the
100m permitted work length. The 16 AWG is specified to insure this condition.
• If this limitation on power drawn from the (yellow) signal cable is a problem, then a
second (black) cable, identical in dimensions to the yellow cable, can be used in
parallel for power distribution only.

2020 IDC317B Notes 81

 AS-I bus- Physical Layer
The slave (or field) modules are available in a number of configurations:
• Input modules for 2-and 3-wire DC sensors or contact closure
• Output modules for actuators
• Input/output (I/O) modules for dual purpose applications
• Field connection modules for direct connection to AS-i compatible devices.
• 12-bit analogue to digital converter.
• 4- channel Pt100 module
• 4- channel analogue input module
• 4- channel analogue output module

2020 IDC317B Notes 82

 AS-I Bus- Physical Layer
• The AS-i network has a transfer rate of up to 167 kbps.
• This is achieved using an access procedure known as ‘master–slave access
with cyclic polling’, where the master continually polls all the slave devices
during a given cycle to ensure rapid update times.
• A modulation technique called ‘alternating pulse modulation’ provides this
high transfer rate capability as well as high data integrity.

2020 IDC317B Notes 83

 AS-I Bus- Data Link Layer
• The data-link layer of the AS-i
network consists of a master
call-up and slave response.
• The master call-up is exactly
fourteen bits in length while
the slave response is 7 bits. A
pause between each
transmission is used for Poll and response frames: master call up
synchronization. and slave response [2]

2020 IDC317B Notes 84

 AS-I Bus- Data Link
• High level data integrity is not possible through conventional error checking
method. This is because AS-i bus information frame is limited in size.
• As-i makes use of a combination of Manchester encoding and Alternating
Pulse Modulation (APM)
• The Manchester encoding is used to transmit synchronising clock information
along the data while the APM incorporates a sine squared waveform for each
pulse.
• The sine squared waveform reduces bandwidth requirements over the
transmission medium and thus permits faster transfer rates.
• The waveform reduces end-of-line reflections as well.

2020 IDC317B Notes 85

 AS-I Bus- Data Link

Data integrity using Manchester encoding and APM [1]

2020 IDC317B Notes 86

 AS-i Bus
• The data integrity is enhances also through an internal set of rules used on
conjunction with the APM coded signal. E.g., the start bit must be a negative
pulse and the stop bit a positive pulse.
• Two subsequent pulses must be of opposite polarity and the pause length
between two consecutive pulses should be 3ms.
• Even parity and prescribed frame length are incorporated at the frame level
as well.
• Thus timing information and high-level data integrity for the AS-i network is
achieved through the combination of frame formatting rules, APM coded
signal and parity checking.

2020 IDC317B Notes 87

 AS-I Bus- Operating Characteristics
• AS-i node addresses are stored in nonvolatile memory, assigned by either the
master or one of the addressing or service units.
• Since AS-i was designed to be an interface between lower level devices, connection
to higher-level systems enables the capability to transfer data and diagnostic
information.
• Plug-in PC cards and PLC cards are currently available.
• Direct connection to a Profibus field network is also possible with the Profibus
coupler, enabling several AS-i networks access to a high-level digital network.
• Handheld and PC based configuration tools are available, which allow initial start-
up programming and also serve as diagnostic tools after the network is
commissioned. With these devices, on-line monitoring is possible to aid in
determining the health of the network and locating possible error sources.

2020 IDC317B Notes 88

 DeviceNet

2020 IDC317B Notes 89

 DeviceNet
• DeviceNet is a low-level device, byte oriented network based on the
controller area network (CAN) developed by Bosch (GmbH) for the
automobile industry.
• Developed by Allen-Bradley. Open network.
• Provides communication link for industrial devices such as limit switched,
photoelectric sensors, bar coded readers, VSDs, motor starters, panel
displays, etc.
• Compared to bit oriented systems such as ASi-bus, byte oriented systems
have a larger addressing capability and larger information content.
• CAN protocol offers fast response and high reliability in demanding
applications, at high temperatures and with high noise immunity.
2020 IDC317B Notes 90
 DeviceNet
• The main aim of DeviceNet network is to reduce the time taken to wire and install
industrial automation devices and provide interchangeability of like components
from multiple vendors.
• DeviceNet can:
• Read state of discrete and analogue devices,
• report temperatures,
• read the load current in a motor starter,
• Change the deceleration rates of drives, or
• Count the number of pakgages that have passed through a conveyor in a certain period.

• Nodes ca be removed or inserted from the network without powering it down.

2020 IDC317B Notes 91

 DeviceNet- Specifications
• Network size: Up to 64 nodes.
• Network length:
Baud Rate Distance
125 kbits/s 500 m
250 kbits/s 250 m
500 kbits/s 100 m

• Data Packets: 0-8 bytes

• Bus topology: linear (trunkline, dropline); power and signal on the same network
cable
• Bus addressing: Peer-to-peer with multi-cast (one-to-many); multi-master and
master/slave special case; polled or change-of-state (exception-based)
• System features: Removal and replacement of devices from the network under
power.
2020 IDC317B Notes 92
 DeviceNet- OSI Model vs DeviceNet
• DeviceNet has a lower level (layer 0) created below the physical later of the OSI
model.
ISO Layer DeviceNet

Application Layer Application Layer Application Layer Specification

Data Link Layer
Data Link Layer
CAN Protocol Specification
Physical Signalling
Physical Layer
Transceiver
DeviceNet Physical Layer Specification
Physical Layer Transmission Media

2020 IDC317B Notes 93

 DeviceNet- Physical Layer
• DeviceNet media consists of a physical bus topology. The bus or ‘trunk’ is the
backbone of the network.
• A 120 Ω terminating resistor is required at the ends of the network
trunkline.
• Drop lines of up to 6 m in length enable the connection of nodes (devices) to
the main trunk line, but care has to be taken not to exceed the total drop line
budget for a specific speed. Branching to multiple nodes is allowed only on
drop lines.

2020 IDC317B Notes 94

 DeviceNet- Physical Layer

DeviceNet Topology

2020 IDC317B Notes 95

 DeviceNet- Cable

[2]

• DeviceNet’s transmission media can be constructed of either DeviceNet thick, thin or flat
cable or a combination thereof.
• Thick or flat cable is used for long distances and is stronger and more resilient than the thin
cable, which is mainly used as a local drop line connecting nodes to the main trunk line.
• The trunk line supports only tap or multiport taps that connect drop lines into the
associated node. Branching structures are allowed only on drop lines and not on the main
trunk line.
• The conventional system uses either a thick or thin cable in cooperating separate twisted
shielded conductor pairs- one pair provides differential data communication and the other
provides power to the device.

2020 IDC317B Notes 96

 DeviceNet- Cable
Wire constraints-
• Thick wire:

• Thin wire:

• Flat wire:

2020 IDC317B Notes 97

 DeviceNet- Device taps

• Sealed taps are available in single port (T type) and multiport configurations.
Regardless of whether the connectors are mini or micro style, DeviceNet requires
that male connectors must have external threads while female connectors must
have internal threads. In either case, the direction of rotation is optional.

Sealed taps[1]

2020 IDC317B Notes 98

 DeviceNet- Device Taps

• Sealed taps are available in single port (T type) and multiport configurations.
Regardless of whether the connectors are mini or micro style, DeviceNet requires
that male connectors must have external threads while female connectors must
have internal threads. In either case, the direction of rotation is optional.

Sealed taps[1]

2020 IDC317B Notes 99

 DeviceNet- Device Taps

• IDC taps: Insulation displacement connectors (IDCs) are used for KwikLink flat cable.
They are modular, relatively inexpensive and compact. They are compatible with
existing media and require little installation effort. The enclosure conforms to
NEMA 6P and 13, and IP 67.

Insulation displacement connectors[1]

2020 IDC317B Notes 100

 DeviceNet- Device Taps
• Open style taps: DeviceNet has three basic forms of open taps. They are:
• Zero length drop line, suitable for daisy-chain applications
• Open tap, able to connect a 6 m (20 ft) drop line onto the trunk
• An open style connector, supporting ‘temporary’ attachment of a node to a drop line.

• Other taps include Multi-port open and power taps.

2020 IDC317B Notes 101

 DeviceNet- Data Link Layer

DeviceNet format frame [2]

2020 IDC317B Notes 102

 DeviceNet
• I/O data transfer among devices on the DeviceNet network occurs only when
connections have been established.
• Instead of atraditional source-destination approach, DeviceNet uses producer-
consumer model.
• In the model, the device with the data produces the data on the network with the
proper identifier. All devices that need data listen for messages. When devices
recognise the appropriate identifier, they process the data.
• With this model, the message is no longer specific to a particular source or
destination, since the identifier provides the means for multiple priority levels,
more efficient transfer of I/O data, and multiple consumers.
• Device thus can be clients, servers or both; clients and servers can be producers,
consumers or both.

2020 IDC317B Notes 103

 DeviceNet- Medium Access
• The medium access control method is described as ‘carrier sense multiple
access with non-destructive bit-wise arbitration’ (CSMA/NBA), where the
arbitration takes place on a bit-by-bit basis on the first field in the frame (the
11 bit identifier field).
• If a node wishes to transmit, it has to defer to any existing transmission.
Once that transmission has ended, the node wishing to transmit has to wait
for 3 bit times before transmitting. This is called the interframe space.
• Despite this precaution, it is possible for two nodes to start transmitting
concurrently.
• Because of this method of arbitration, the node with the lowest number (i.e.
the most significant ‘0’ s in its identifier field) will win the arbitration.

2020 IDC317B Notes 104

 DeviceNet- Fragmentation
• Any device that needs more than 8 bytes of data sent in any direction will cause
fragmentation to occur. This happens since a frame can only contain 8 bytes of
data.
• When fragmentation occurs, only 7 bytes of data can be sent at a time since the
first byte is used to facilitate the reassembly of fragments. It is used as follows:
First byte Significance
00 First fragments (number 0)
41- 7F Intermediate fragments
(lower 6 bits of the byte is the
fragment number)
80 - FF Last fragment
(lower 6 bits of the byte is the
fragment number)

2020 IDC317B Notes 105

 DeviceNet- Application layer
• The main protocol at the TCP application level (layers 5, 6 and 7 in the OSI model) is CIP the
‘control and information protocol’.
• CIP gives generic DeviceNet an ‘industrial functionality’ and allows the control, collection
and configuration of data. It also allows a producer-consumer model to run on CANBUS, or
whatever technology being used at layers 1 and 2.
• CIP provides the following common features for users of DeviceNet, ControlNet and
Ethernet/IP:
• It provides the user with a standard set of messaging services for all three networks.
• It lets the user connect to any network and configure and collect data from any
network.
• It saves time and effort during system configuration because no routing tables or added
logic are necessary to move data between networks.
• It reduces the amount of training needed when moving personal between different
networks by providing similar configuration tools and features.

2020 IDC317B Notes 106

Reference
• Steve Mackay, Edwin Wright, Deon Reynders and John Park. Practical Industrial Data Networks: Design, Installation and
Troubleshooting. All with IDC Technologies, Perth, Australia First published 2004, IDC Technologies.
• Mick Crabtree. Industrial Communication Handbook. Jenny Warkwick, Crown Publications cc. 2008. 3rd Edition.
• Process Software and Digital Networks. INSTRUMENT ENGINEERS’ HANDBOOK. Third Edition, 2002 by Béla Lipták
• Schneider Electric Presentation: Industrial networks. Needs and available components. Technologies. Schneider Electric
policy

2020 IDC317B Notes 107