FF Physical Layer Components - Fieldbus · PDF fileFF has the physical layer specification as...

Name Chakravarthy Akella

Job Title Dy. Manager S&S

Company Pepperl+Fuchs

Bangalore

FF – Physical Layer Components

© 1994 – 2011 Fieldbus Foundation 2

Agenda

- Introduction

- FF Basics

- FF Zone1 and Zone2 Topologies

- System commissioning and maintenance


Conventional Instrumentation

4-20mA technique:

Ethernet TCP/IP

Ethernet/TCP/IP Internet/Intranet Work

station

Operations Maintenance

PC/VME Management

Factory

level

Cell-

level

Field-

level

Ex


Fieldbus Instrumentation

Ethernet TCP/IP

Operations Maintenance

Cell-

level

PC/VME Management

Ethernet/TCP/IP Internet/Intranet Work

station

Factory

level

Fieldbus EX Fieldbus

Field-

level


Expanded View of Process & Instruments

1. Self Diagnostics and communication capabilities of microprocessor based

fieldbus devices helps reduce downtime and improve plant safety.

2. Plant operation and Maintenance personnel can be notified and corrective

actions taken quickly and safely.

Fieldbus Extends View to Field Instrument Traditional 4-20mA View stops at I/O Subsystem

PV

Control System Network

4-20mA

Control System Network

H1

Analog Controller Fieldbus Controller

PV , Mode , Variables , Alarm

Diagnostics , Etc I/O Subsystem


FF Design Guides

International Codes and Standards

International Electro technical Commission (IEC)

IEC 61158-1 Introductory Guide

IEC 61158-2 Physical Layer Specification and Service Definition

IEC 61158-3 Data Link Layer (DLL) Service Definition

IEC 61158-4 Data Link Layer (DLL) Protocol Specification

IEC 61158-5 Application Layer Service Specification

IEC 61158-6 Application Layer Protocol Specification

IEC 61158-7 System Management

IEC 61158-8 Conformance Testing

IEC 600079-11 (IEC 60079-27) Fieldbus Intrinsically Safe Concept (FISCO)


Foundation Fieldbus Design Guides

Foundation Fieldbus compliance Specification

www.fieldbus.org

FF-569 Host Interoperability Support Test

FF-831 Fieldbus Specification for Power Supplies and Conditioners

FF-844 Fieldbus Specification for Cable

FF 846-1.1 Fieldbus Device Couplers used at Zone2 and Zone1

AG 181 System Engineering Guidelines (Rev 3.1)

http://www.fieldbus.org/


Fieldbus Physical Layer Design Guides

FF has the physical layer specification as per IEC 61158-2:

Transmission rate of 31.25 kBit/s

Total cable (Trunk + Spurs) distance of 1900m maximum

Maximum spur length 120 m upto 12 devices

Up to 32 devices per segment (Host + 31 field)

Manchester II coding used to transmit data

Data transmission by a ± 9mA modulation signal

Minimum working voltage 9 Volts ( Range is 9-32V) and average current consumption 20mA per device


Output Cable Length

No. of communication elements Max. spur output cable length

1 – 12 120m

13 – 14 90m

15 – 18 60m

19 – 24 30m

25 – 32 1m


Where is Exe protection required at the

Process Field

■Field Enclosure mounted at Zone2, and Zone1

-Mechanical Impact test

-IP rating

-Material Grade

-Drop test

-Vibration test

■Any Fieldbus cable system installed at Zone2, Zone1

- IS cables ( for operational reasons)

- non-IS cables

- Armor or conduit wiring are common practice


Application - Zone1 installations

Non-IS(EEx e)

– Trunk and spurs must be installed in increased safety EEx e

IS ( Limted Power and High Power)

Limited power

– ENTITY and FISCO concepts

High Power

– HPT

Trunk has to be installed in increased safety

Spurs are intrinsically safe

Allows the use of Non IS Power Supplies and IS FieldBarrier

– HPT-IS

Trunk and Spurs are IS


Application Area - Zone 1 (EEx d)

Segment Protector Ex me

Zone 1

16..32V

16..32V

230VAC

Fieldbus

Power Hub

Ex e

Instruments

Ex d

Live Disconnect Switch


User Benefit : Design guidelines


IS Fieldbus

High power ( Exe + IS )

High Power IS

Refer AG 181-3.1

-Limited Power

-High Power


Application Area - Zone1 IS ENTITY

20..35V 230VAC

Zone 0/1

V = 10.5V

I = 70mA

ENTITY Device Trunk cable < 200m

Number of devices less than 2

No load sharing Redundancy at Power Supply

9V

23mA

ENTITY FF

Power Supply


Application Area - Zone1 IS FISCO

20..35V 230VAC

Zone 0/1

V = 12.5V

I = 100mA(IIC)

I = 245mA (IIB)

FISCO Device Trunk cable < 400m



9V

23mA

FISCO FF Power

Supply


Can FISCO/ENTITY power supply be Redundant?


Standby FISCO Concept

Zone 0/1

FISCO Device Trunk cable < 400m



Same limitations as per FISCO concept

9V

23mA

FISCO FF Power

Supply

A

B


Zone 1

Zone 0/1

Ex e

Ex ia (FISCO + Entity)

FieldBarrier

16..32V

16..32V

230VAC

Fieldbus

Power Hub

Application Area - Zone1 IS - HPT

Exd Trunk live disconnect switch


High power trunk or FieldBarrier concept

Trunk is Ex e( increased safety) and Spurs intrinsically safe

Spurs as per FISCO or Entity IS

Longest cable run possible 1900m(Trunk+Spurs) and 120m Spur

No limitation of voltage and current on trunk

Redundant power supplies possible

Trunk could be live disconnect with approved Exd Switch

Hazardous area application with the least difficulties

Application Area - Zone1 IS HPT


DART Application : IS Fieldbus

The first step

Simplifying

validation

MAX power + FISCO

High Power Trunk Intrinsic Safety


Simple DART circuit

Ex ib IIC

Time to turn-off: 5…10 µs


IF

UF

PF

Initial

Phase Critical Phase

Spark duration tF: 5 µs…2 ms t

U

di/dt

Typical Spark – Physics

Spark voltage

Spark current


IF

UF

PF

Initial

Phase Critical Phase

Spark duration with DART tF ≤ 5 µs

U,

I, P

t

Typical Spark – Turned Off by DART


DART High Power Intrinsic safety

Provides 8…50 W, intrinsically safe

Detects sparks as they occur

Limits the energy during a fault

Could be used at Conventional(50W) and Fieldbus(8W)

Applications

A completely intrinsically safe fieldbus segment in

gas groups IIB and IIC with real power redundancy and advanced

diagnostics.

The Intrinsically Safe High-Power Trunk


DART (HPT-IS) FIELDBUS STRUCTURE

IS Segment Protector

Zone 1/ Zone2

22.5V

360mA

Intrinsically Safe –

Trunk up to 1000m

DCS

-------

Upto 16 IS devices

Each Spur upto

120m


Fieldbus Design and validation

Factory Acceptance Tests

– Termination

– Communication

– Parameter measurements

– Segment operation – all typical segments

Site Acceptance Tests

– Network validation

– Noise – Watch out for Frequency Drives

– Electrical characteristics

– Grounding and shielding

– System Functional Tests

– Cable check

– Device parameters measurements

– Signal patterns etc


Commissioning until now

Always on the critical path

Manual, step-by-step procedure

Labor intensive

Requires

– Screw driver

– Check sheet

– Pencil

– Multimeter - FF testers

– Oscilloscope

Connect one device at a time

Disconnect after testing

Test Report


Integrated and Portable Advanced Diagnostics

Portable Advanced Diagnostics Integrated at Fieldbus Supply

Advanced Diagnostics

Stand Alone


Maintenance View

Alarm window view

Network view

Segment-specific status of the physical layer

ADM status view with PRM TAG

FF-Segment

FF-Host


Simple Commissioning Steps with ADM

Verify address setting

Wire up devices in the right location

Check shielding

Activate communication

Use automated work procedures

– Testing

– Documentation

All devices at once

Wiring remains undisturbed!

Commissioning Wizard

Test

Report

x


Commissioning Wizard

With Expert System Support

Takes snapshot

Identifies wiring erros

Ensures compliance with

AG181 and IEC 61158-2

Recommends limits for ADM messages

Stores limits in non-volatile memory

Automatic Tag Readout

Creates baseline report:

Snapshot of all measurements

Complete documentation

Saves 80% of pre-commissioning time


Diagnostic Menu

Expert System delivers clear text

information for fast fault finding

1 Active messages

2 Actionable information with

solution guideance based on

expert system

3 History with timestamps

When the failure…

… occured

… disappeared

Export function for external

analysis and storage

1

2 2

3


Online monitoring

Clean layout shows boundaries

Displays measurement values

Highlights violations with color coding:

Issues diagnostic messages

Good value

Maintenance required

Out of specification


Online trending and history

Monitoring

Reveals long term changes

Exports into many formats


Built-in fieldbus oscilloscope

ADM provides expert tools

for fast fault finding

For diagnosing complex scenarios

For the fieldbus expert

With fieldbus specific triggers

Captures up to 10 shots in a row


Questions


THANK YOU

FF Physical Layer Components - Fieldbus · PDF fileFF has the physical layer specification as...

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