Post on 28-Aug-2020
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 1
Connecting Fieldbus Power and Knowledge
Robby Bosgaerd
®
PROCESS FIELD BUS
PEPPERL+FUCHS 2
Proven fieldbus solutionsIntrinsic safety expertsFlexible configurationsReliable data transfer
®
PROCESS FIELD BUS
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Standard Point-To-Point Intrinsic Safety Isolation Barriers PTP
Remote I/O with Integrated Intrinsic Safety Barriers PTB
Intrinsically Safe Remote I/O PTB Intrinsically Safe Fieldbus BTB
Available Technologies
Hybrid Field I/O Solutions
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P
Standard Point-to-point• Many specialty barriers• Huge field product selection• Good technology for small
facilities• Easy to use• Suitable for critical loops and
shutdown circuits• Simple upgrades• Control room or field
installation• No validation issues
Controller
Hazardous AreaZone 0/1
Zone 2
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Controller
Remote I/O with IS barriers Point-To-Bus
• Standard field circuits• Huge field product selection• Mid-range complexity for
most facilities• Similar to standard remote
I/O• Reduced installation cost• Low ownership cost
Hazardous AreaZone 0/1
Zone 2
Profibus DPE, Modbus,Modbus Plus,
ContolNet, Ethernet
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Intrinsically Safe Remote I/O Point-To-Bus• Huge field product
selection• Mid-range complexity for
many facilities• Superior technological
solution• Similar to standard remote
I/O• Low installation cost• High functionality
Controller
Hazardous Area Zone 1
Zone 0/1
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• Upper range technology for many facilities
• Superior technologic solution
• Low installation cost• High functionality
Intrinsically Safe Fieldbus Bus-To-Bus
Controller
Hazardous Area
Zone 0/1
Profibus PA,Foundation Fieldbus H1,AS-Interface
Profibus DPE,Foundation Fieldbus H1
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 8
Fieldbus History
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PROCESS FIELD BUS
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Profibus-Master
Siemens S7 ET200
Gateway 1Profibus-DP/ASi
Gateway nProfibus-DP/ASi Batch-Controller...
ASi-EX2E/A
...
ASi-EX4E
...
ASi-EX2E/A
...
ASi-EX2E/A
...
......
process
Factory Automation As-i bus
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Side look toFactory Automation
P2P
Remote I/O
1990
BUS
Remote I/O
P2P
2010
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Estimation forProcess Industry
P2P
Remote I/O
2000
BUS
Remote I/O
P2P
2010
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Why Fieldbus was not yet fully used in Process Automation?
Not all field devices are already available with integrated fieldbus interface.
The limited power on an intrinsically safe fieldbus limits the number of field devices to a theoretical quantity of 10 which in practice are very often less than 5 devices.
Several low value field sensors will not justify the fieldbus integration at all.
Approach from vendors came from Factory Automation = reduced wiring cost
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Available System
Different systems PROFIBUS-FMS PROFIBUS DP (V1) PROFIBUS PA
Different physics RS 485 Fibre optic IEC 61158-2
Different Systems H1 Bus H2 Bus (Fast
Ethernet/High Speed Ethernet)
Different physics IEC 61158-2 (H1)
• With power supply• Without power supply
Fibre optic Fast Ethernet (H2; HSE)
PROFIBUSPROFIBUS FOUNDATION FieldbusFOUNDATION Fieldbus
Com
mun
icat
ion
Syst
ems
Com
mun
icat
ion
Syst
ems
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PROFIBUS Application Range
CNCPC/VME
VME/PCPLC PLS
Factorylevel
Bus CycleTime
< 1000 ms
Cell-level
Bus CycleTime
< 100 ms
Bus CycleTime
< 10 ms
Field-level
Ethernet/TCP/IP Internet/IntranetWorkstation
Ethernet TCP/IP(Industrial Ethernet, PROFInet?
PROFIBUS DPPROFIBUS PA or PROFIBUS DP
AS-Interface
Communication SystemsCommunication Systems
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FOUNDATION Fieldbus Application Range
PC/VME
OperationsPLC
Factorylevel
Cell-level
Field-level
Ethernet/TCP/IP Internet/IntranetWorkstation
Ethernet TCP/IP (HSE)
H1-Bus Non IS H1-Bus IS
BridgeMaintenance
Management
Communication SystemsCommunication Systems
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 16
Fieldbus Architecture
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Real Line Topology
If a field device must be replaced (e. g. depending on a defect) the transmission cable must be interrupted.Minimum all field devices „right“ from the defective field device will
fail additional all field devices „left“ from the defective field device will
continue the communicationTo avoid this, Junction Boxes are required
Power supply or segmentcoupler
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Line Topology with Spurs
For this topology Junction Boxes are requiredSupported cable length = 1900 mCable legth = legth of trunk + sum of all spurs
Spur legth < 120 mExample:
10 spurs with 120 m each max. trunk length = 700 m
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Structure of an Intrinsically SafeFieldbus System
The max. number of participants depends on Output current of the Power Repeater Real current consumption of the participants Voltage drop along the cable Type of explosion protection model
• FISCO model• Entity model
ExternalFieldbusterminator
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Difference between FISCO and Entity
Lcable
Ccable
FISCO model: Cable is a „distributed“ inductance and capacitance
Entity concept: Cable is a „concentrated“ inductance and capacitance
dR dL dL dLdR dRdC dC dC
Distributed reactances
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FISCO Model
Fieldbus Intrinsically Safe Concept
Basics IEC 61158-2 All participants, except the Power Repeater, works as a current
sink (passive) Only one active device per segment is allowed The values Ui, Ii and Pi of every field device must be higher than
the values U0, I0 and P0 of the Power Reeder (basics of intrinsic safety)
The values Ci and Li of every field device must be smaller or equal than 5 nF bzw. 10 µH (negligible small; problem of Developer!)
The minimum supply current consumption per participant is 10 mA (typical value 12.8 V; 100 mA for EEx ia IIC)
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FISCO Model Preconditions
The cable must have the following values Resistance load per unit length R‘: 15 ... 150 Ω/km Inductance load per unit length L‘: 0,4 ... 1 mH/km Capacitance load per unit length C‘: 80 ... 200 nF/km
• C‘ = C‘ lead/lead + 0,5*C‘ lead/shield, if both leads are working potential free (floating circuit)
• C‘ = C‘ lead/lead + C‘ lead/shield, if one of the leads is connected to the shield
Max. cable length 1000 m for EEx ia IIC / 5000 m for EEx ib (Theory, will be checked in the moment)
Max. spur cable length 30m (will be changed to 60m) Fieldbus terminator R = 90 ... 100 Ω C = 0 ... 2,2 µF
PRO
FIB
US
DP/
DPV
1/PA
PRO
FIB
US
DP/
DPV
1/PA
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Proof of Intrinsic Safety
If you have to verify the Intrinsic Safety Choose a Power Repeater in acc. to FISCO model Choose only Field Devices in acc. to FISCO model Choose a transmission cable in acc. to FISCO model Verify
• UO (Power Repeater)< Ui (of every Field device)• IO (Power Repeater) < Ii (of every Field device)• PO (Power Repeater) < Pi (of every Field device)
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IS and Output Parameters
Repeaters
Concept U0 [V] I0 [mA] P0 [W] US [V] IS [mA] Cable Length[m] @
Entity 12,8 140 1.2 10.6 75 500
FISCO 15 207 1.93 12.6 110 750
non-I.S. -- -- -- 24 400 850
* @ IS, cable specification 18 AWG line type A, q=0,8mm2, 44Ω/km
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Why Segment Protectors?
What happens if there is a short on a trunk?
The complete segment will fail
Solution: Segment Protector Segment Protectors do have a current limitation (45 mA)
at the spur output
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Segment Protectors
To avoid problems in case of a short on a fieldbus segment it is possible to use active Segment protectors
If a Segment Protector is in use, a short at a spur has no effect to the trunk
A Segment Protectors Causes an additional voltage drop (< 1.5 V) Do have a current consumption (< 7 mA)
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Problem with IS Applications
Power Repeater with IS Interface limits the number of participants per segment to less than 10 field devices (FISCO model) to less than 6 field devices (Entity concept)
Intrinsic Safety limits the cable length to less than 1000 m (FISCO model) ??? depending on the available capacitances and inductances
This requires a lot of Power Repeaters
Solution
FieldBarrier
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FieldBarrier
Hazardous Area
EEx e wiring
EEx ia IICoutputs
Standard PowerRepeater with24 V; 400 mA
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Cable lenth per Spur
1 m1 m1 m1 m25 – 32
1 m1 m1 m30 m19 – 24
1 m1 m30 m60 m15 – 18
1 m30 m60 m90 m13 – 14
30 m60 m90 m120 m1 – 12
4 devicesper spur
3 devicesper spur
2 devicesper spur
1 device
per spur
No. of Participants
Based on cable type A
Functionality between No. of participants and spur lengthFunctionality between No. of participants and spur length
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Types of cables
a = not specified
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Topology with Power Repeater
A Power Repeater opens a new H1 segment Each segment can have
Cable length up to 1900 m 32 participants (today no LAS can handle this amount of field
devices) Depending on the type of Power Repeater it is possible to open a
segment for hazardous area applications
Integrated terminator
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Power ConditionerTo non-powered H1 Host Ports 4A Redundant
Power Supplies
24 VDC
Fault Output Fault Output
24 VDC
Optional 24VDC Power connection on module if power feed modules are not used!
1A powered H1 each
Field Devices
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FTFT
H2 PROFIBUS DP 9,6kBit/s - 12MBit/s
20-35V
. . .
Up to
4x PA Master
20x PLM´s
Bridge
H1 IEC-61158-2
I.S.
H1 IEC61158-2
non I.S.
1...5 PLMPA Master Channels
Div 2 /Zone 2
1...5 PLM
RLM
Architecture
Segmentcoupler 2nd. Generation
®
PROCESS FIELD BUS
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Advantages
Up to 125 PROFIBUS PA devices connectable
4 independent PROFIBUS PA Master integrated up to 20 PROFIBUS PA Segments with up to 200
PROFIBUS PA slaves (Theory!!!, not addressable!!!) „Adjustable“ PROFIBUS PA cycle time
Variable mixture of IS and Non-IS power links
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 39
What about discrete I/O?
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PROCESS FIELD BUS
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Remote I/O
Price Device
Price Bus Connection
100%
50%
0%
Analog Valve
Diff. Presure
Transmitter
Temperature
Transmitter
On/Off Valve
On/Off Valve with
zone 2 Remote I/O
On/Off Valve with
Zone ! Remote I/O
Thermocouple
PT100
Proximity Sensor
Mechanical Contact
Economical justificationto use a fieldbus connection
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Valve Coupler
Field Process Interface, FPI
Features:4-Channel solenoid driverTwo discrete inputs per output channel for valve positionIP65, -20 ºC…+70 ºCZone 1 / Division 1 mounting, EEx ia IIC T4Bus powered 23 mA current consumptionMust be used with Low powered valves 6 V / 1.5 mAAdvantages:Cost effective solution, turns standard valves into”SMART”
valves for preventive maintenanceGets more valves on the FieldbusCan be used with inductive sensors and mechanical contactsEasy to installWide range of diagnostic and maintenance functions:
lead breakage, short circuit, counter,travel time and breaktime.
®
PROCESS FIELD BUS
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 42
Fieldbus TopologiesFieldbus Topologies
Junction Box Junction BoxJunction Box
Power Supply / Segment coupler
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Junction Box Junction BoxJunction Box
Power Supply/ segment coupler
SegmentProtector
FieldBarrier
Fieldbus TopologiesFieldbus Topologies
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 44
Junction Box
Power Supply/ segment coupler
FieldbusProcess
Interfaces
FieldBarrierSegmentProtector
Fieldbus TopologiesFieldbus Topologies
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FieldBarrierFieldBarrier + + Valve CouplerValve Coupler
Zone 1
Zone 0
Red. Power Supply
To H1 Host
EEx e
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Werner SetzweinBASF AG:
Savings on DCS investmentwith RI/O and Fieldbus
100 %
75 %62,5%
Conventional Remote I/O Fieldbus
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Surge Protection
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
Possibility 1: Highest degree of protection
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Surge Protection
The truth will be anywhere in between, depending on Real topology Philosophy of the customer ...
Possibility 2: Lowest degree of protection
SP
SP SP
SP
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FieldConnex in OperationFi
eldC
onne
x S
yste
mFi
eldC
onne
x S
yste
m
FieldBarrier Topology and pneumatic valve coupling – ready to be connected
PEPPERL+FUCHS 50Mar
keti
ng T
ools
Mar
keti
ng T
ools
System Catalogue cover
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EEx nL
EEx nL is a „simplified“ version of intrinsic safety(L= energy limitted)
A simplified proof of intrinsic safety is required
Ii<IO = 45 mA
Pi<PO = 1.485 W
Ui<UO = 33 V
Field DeviceSegment Protector(preliminary)
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Problem
To fulfil the EEx nL requirements it is mandatory to have a voltage limitation in accordance with EN 50021 EEx nL!!! Declaration of Manufacturer or Declaration of Conformity is
required. Perhaps you it can be used by you?
Category 3(Zone 2)
UO = 33 VIO = 45 mA
Ui = 24 VIi = 75 mA
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FNICO Concept
IEC 60079-27 Electrical apparatus for explosive atmospheres – Part 27: Fieldbus intrinsically safe concept (FISCO) and Fieldbus non-incendive concept (FNICO).
Will be adopted in 2004
Differentiation FNICO Category 3 (Zone 2) applications in EEx nL FISCO Category 1 and 2 (Zone 0 and 1) applications
in EEx i
Fieldbus Non-Incendive COncept
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Preconditions of FNICO
Basics IEC 61158-2All participants, except the Power Repeater works as a current
sink (passive)Only one active device per segment is allowedThe values Ui, Ii and Pi of every field device must be higher
than the values U0, I0 and P0 of the Power Repeater (basics of intrinsic safety)
The values Ci and Li of every field device must be smaller or equal than 5 nF bzw. 20 µH (negligible small; problem of the developers!)
The current consumption from te fieldbus cable must be for each field > 10 mA.
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FNICO Model Preconditions
The cable must have the following values Resistance load per unit length R‘: 15 ... 150 Ω/km Inductance load per unit length L‘:0,4 ... 1 mH/km Capacitance load per unit length C‘: 45 ... 200 nF/km
• C‘ = C‘ lead/lead + 0,5*C‘ lead/shield, if both leads are working potential free (floating circuit)
• C‘ = C‘ lead/lead + C‘ lead/shield, if one of the leads is connected to the shield
Max. cable length 1000 m for EEx ia and 5000 m for EEx ibMax. spur cable length 60 m per spur
This will also be changed in the FISCO model Fieldbus terminator
R = 90 ... 100 Ω C = 0 ... 2,2 µF
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FNICO Model
If the preconditions, described in the previous sheets, are matched, the proof of Eex nL will be reduced to
U0 < Ui
I0 (in acc. with ignition curve) < Ii (in acc. with ignition curve)
P0 < Pi
„Power Supply“ Field device
Robby Bosgaerd Key Account Manager Pepperl-Fuchs PEPPERL+FUCHS 57
Connecting Fieldbus Power and Knowledge
Robby Bosgaerd
®
PROCESS FIELD BUS