FF Physical Layer Components Best PracticesBest Practices · Evolution of Various FF Hazardous Area ... – Screw driver – Check sheet D D – Pencil ... Simple Commissioning Steps

FF Physical Layer ComponentsBest PracticesBest Practices

Binoy KamathAGM – Project Pursuit

© 2011 Fieldbus Foundation

jPepperl+Fuchs India Pvt. LTd.,Bangalore

AgendaAgenda

Introduction to FF and FF Physical Layery yFF Physical Layer Components FF Wiring Topologiesg p gFF Segment DesignFF Monitoring and DiagnosisFF Monitoring and DiagnosisSummary and Conclusion


AG181 REVISION 3.1 Official FF Design GuidelinesAG181 REVISION 3.1 Official FF Design Guidelines


What is Fieldbus?A Fieldbus is a digital, two-way, multi-drop communication link amongintelligent measurement and control devices. It serves as a Local AreaNetwork (LAN) for advanced process control remote input/output and high-Network (LAN) for advanced process control, remote input/output and highspeed factory automation applications.

HOST Field Device

How Do we build the network?


Physical Layer Components y y p

HOST

Wiring BlockWiring Block FIELDBUS

TERMINATORFf POWER S

JUNCTION BOXSUPPLY BOX

Spurs

SURGE PROTECTOR

PROCESSINTERFACE

Home Run Spurs

CONVENTIONAL FIELD DEVICES

FIELDBUS DEVICES


Physical Layer and Its Components

The Physical Layer receives messages from the CommunicationsStack and converts the messages into physical signals on thefieldbus transmission medium, and vice-versa.

FF Power SupplyFF Power SupplyFF Cables FF Wiring BlocksFF Surge ProtectorFF Terminators


FF Power SupplyFOUNDATION Fieldbus Power Supplies (6.2.2 – AG 181 v3.1)

FOUNDATION fieldbus power supplies are specialized power suppliesFOUNDATION fieldbus power supplies are specialized power suppliesthat provide both the segment isolation from bulk power and thepower conditioner in one unit.

Power conditioning prevents the bulk power supply from shorting outPower conditioning prevents the bulk power supply from shorting outthe communications signal, preventing the segment from functioning.

Isolation prevents ground loops and interference among segments.

They shall have the appropriate approval: FF-831 “FOUNDATIONSpecification; Fieldbus Power Supply Test Specification” andassociated check mark

FOUNDATION fieldbus power supplies should be redundant, loadsharing and output current limiting, and provide facilities formonitoring faults and failures. .


FF Power Supply – General Purpose and With DCS System ConnectorsSystem Connectors

APPROVEDAPPROVED


FF Power Supply – Recommendations pp y

Each Segment shall have a dedicated FFPSFFPS shall be modular and hot SwappableFFPS shall be Isolated, Redundant and Load SharingFFPS shall provide facilities for monitoring faultsand failuresand failuresFFPS rating shall allow longer home run / Trunklength to benefit user


FF Wiring BlocksFF Wiring Blocks


FF Wiring Blocks gFOUNDATION fieldbus Wiring block is located wherethe trunk (home run) is connected to the variousthe trunk (home run) is connected to the variousdevice spurs.


FF Wiring Blocks - SummaryOnly registered FOUNDATION fieldbus Wiring blocks shall beused

g y

The couplers shall have built-in spur short-circuit protection (tominimize the impact of a short at one device affecting the wholesegment)segment)

Spur short-circuit protection shall have visual indication (on aspur level) when short-circuit protection is active and thespur level) when short circuit protection is active and thespur's maximum current shall be limited by area classificationand the current available to the network

The couplers should provide visual indication of segmentpower as a minimum


FF CablesFF Cables


Types of FF CablesypThe Physical Layer Specification of FOUNDATION

Fieldbus defines four types of cablesFieldbus defines four types of cables

Type AType BType BType CType D

The max. cable length per segment of 1900m( trunk+ Spurs) could be reached with cable type A only!

In the meantime there are cables available type Awith different cross sections


Types of Cablesyp


a = not specified

FF Surge ProtectorsgSurge Protection ( 6.4 AG 181 V3.1)

Surge protection for FOUNDATION fieldbus devices may berequired in areas where induced voltage is an issue.

Thi i l d h l i i i it hThis includes areas such as close wiring proximity wherelarge inductive loads are started and stopped, or areas knownfor lightning incidence.

Surge suppression consists of a low-capacitance deviceinstalled at the device's electrical connection. It shall normallyappear as an open circuit to the spur and segment to preventpp p p g pany adverse effect on communications.


FF Surge Protectorsg


FF Surge Protectors - Summary

Surge suppression device should not measurably attenuate the fieldbus signal

g y

attenuate the fieldbus signal

Shall be installed at the Field Devices and host H1Shall be installed at the Field Devices and host H1 Interface

Current-limiting couplers ( Wiring Block spurs ) should not be used in combination with surge protectors. The surge protectors will cause failure ofprotectors. The surge protectors will cause failure of the current limiting circuits when a lightning strike occurs


FF Terminators

FOUNDATION fieldbus segments require EXACTLY two terminators,one at each end of the trunk (home run) cable. The terminator is( )comprised of an RC network that provides 100 Ω impedance.

The terminator allows the current-based FOUNDATION fieldbuscommunications signal to be viewed as a voltage while being offset ong g gthe DC segment voltage supply.

Most fieldbus power supplies and/or wiring blocks have a built-in segmentterminator. Some wiring components have switchable terminators.g pTerminators at a field device shall not be used (due to the impact on thewhole segment should the device need replacement)


FF Wiring Topologiesg p gSpur Topology (Bus with Spurs)

This topology consists of fieldbus devices connected to a multi-drop bus segment through a length ofThis topology consists of fieldbus devices connected to a multi drop bus segment through a length ofcable called a spur. This technology is technically acceptable, but generally not a good economicalchoice when there is a high density of devices.

Combination TopologyCombination TopologyCombinations of the above topologies must follow all the rules for maximum fieldbus network/segmentlength, and include the length of spurs in the total length calculation. These types of topologies arepreferred for designs using bricks with tray cable. Spurs are permitted to extend only from trunk linesand not from other spur lines.


FF Wiring Topologiesg p gDaisy Chain TopologyThis topology consists of a network/segment that is routed from device to device, andis connected at the terminals of the fieldbus device. It should not be used, as it isunacceptable, for maintenance purposes.


FF Wiring Topologies in Practice


General Purpose / Safe AreapAccurate short circuit current limitation for

each channel with LED i di ti

HOST DCSindication

FFPS

SafeA fault at one

FFPS Redundant

/ Load Sharing Safe

areaA fault at one

instrument (e.g. short circuit) has no impact on the

16..32V

16 32V

Sharing


pother outputs or on

the segment230VAC

16..32V

230VAC

Fieldbus in Hazardous AreaRedundant FISCO

The first step

Simplifying validation

MAX power + FISCO

Re-inventing Intrinsic Safety


Re-inventing Intrinsic Safety

Zone 2 Topologyp gyZone2

Previous standardsPrevious standards

-Ex nA ( Non arcing) / Ex nL ( energy Limiting) / Exic Intrinsically Safe

-FNICO ( Non-Incendive)

Current standard – Exic

From 2007 onwards Ex nL and FNICO standards are omitted and replaced by Ex ic ( similar to IS)


Zone 2 Hazardous Area Concept Ex nL / Ex icpAccurate short circuit current limitation for

each channel with LEDHOST DCS each channel with LED indication

Ex nA

Ex nL / ic17 to 30V

A fault at one Zone2

17 to 30V, 500mA

A fault at one instrument (e.g. short circuit) has no impact on the

16..32V

16 32V

Zone2


pother outputs or on

the segment230VAC

16..32V

230VAC

AG181 REVISION 3.1 Official FF Design GuidelinesAG181 REVISION 3.1 Official FF Design Guidelines


Zone1 Topologyp gy

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

IS ( FISCO, HPT, DART)

A full intrinsically safe fieldbus segment (FISCO)– Intrinsic safe trunk and spur– Requires the use of IS Power Repeaters/Power Link module– Requires the use of IS Power Repeaters/Power Link module

A mixture of EEx e and EEx I (High Power Trunk)– Trunk has to be installed in increased safetyy– Spurs are intrinsically safe– Allows the use of Non IS Power Supplies/Power Repeaters/Power

Links


High Power Intrinsically safe (DART)

Application Area - Zone 1 (EEx d)pp ( )

Segment Protector Ex meFieldbus Power HubPower Hub

Ex e

16..32V

16..32V230VAC InstrumentsEx d


Zone 1R-SP-E12 is resin filled as per Exd installation requirements

Application Area - Zone1 IS - HPTResin Filling for Zone 1 Installation

FieldBarrier

pp

Exd Trunk live disconnect switch

Installation

Zone 1

Fieldbus Power Hub

Ex e

Ex ia(FISCO + Entity)

Zone 0/116 32V

16..32V

230VAC


16..32V230VAC

Zone1 IS Enclosure solutions

FieldBarrierFieldbus

Zone 1

Power Hub

Ex e

Ex ia(FISCO + Entity)

Zone 0/116 32V

16..32V

230VAC


16..32V230VAC

DART Fieldbus

DART FieldbusThe Simplicity of Intrinsic SafetyDART FieldbusThe Simplicity of Intrinsic Safety

DART fieldbus provides:

The Simplicity of Intrinsic SafetyThe Simplicity of Intrinsic Safety

A completely intrinsically safe fieldbus segment in gas groups IIB and IIC with real power redundancy with load sharing and advanced diagnosticswith load sharing and advanced diagnostics

The Intrinsically Safe High-Power Trunk


The Intrinsically Safe High Power TrunkDART Fieldbus is certified according to the international I.S. standard IEC 60079-11

DART: Intrinsically safe High-Power Trunk

General Purpose AreaZone 2

y g

R d d t th t i l t dRedundant, three-port isolatedDART Power Supply

The intrinsically safe High-Power Trunk

DART Segment Protectors

protected by DART®

Intrinsically safe spursEx ib IIC with S/c

Z 1

Ex ib IIC with S/c protection


Zone 1

Evolution of Various FF Hazardous Area Topologies

Safe Area FISCO / FNICO FISCO Redundant HPT Field Barrier DARTSafe Area FISCO / FNICO FISCO Redundant HPT Field Barrier DART

Segment Current + + +Segment Voltage + + +Segment Voltage

Redundancy

Load Sharing FFPS

Physical Layer Diagnostics

Segment Design Mix

C bi t S + +Cabinet Space + +Initial Segment Cost (FFPS + Wiring Blocks) + + +Live Trunk Working


g

: Available : Not Available + : High : Low

FF Segment Designg g

H t d i F d ti Fi ldb t ?How to design Foundation Fieldbus segments?


Segment Design and Validation Tools

• Fieldbus allows to connect many devices on the same bus cable butsame bus cable, but…

How many devices can I really connect?• How many devices can I really connect?

• What cable should I use and what cable distances• What cable should I use, and what cable distances can I really achieve?

• What happens in case of a short circuit in the field?


Segment Design and Validation Tools

• Graphical segment design tool example

• Download the NEW DesignMATE segment verification tool• Download the NEW DesignMATE segment verification tool

• www.segmentchecker.comwww.segmentchecker.com

• Various other tools are available with FF Vendors




FF Physical Layer Monitoring and Diagnosis


Fieldbus Diagnostic Capabilities Have Evolved ARC ReportEvolved – ARC Report


Typical problems – and how to solve them

Tools to measure segment parameters

y

(voltage, current)Tools to measure segment health(termination, noise)Tool to display EMC problemsTools to test communicationTool to measure cable degradationTool to measure cable degradationover time (trending)Tool to visualize signal quality ofindividual devices (noise jitter telegram level)individual devices (noise, jitter, telegram level)Tool to allow remote access for expert


With Diagnostics of Physical Layer We Can….g y yCommission SegmentsMonitor Segments OnlinePredictive Fault finding of Segments

SEE what's going on in your physical layerKNOW h d h t t

SEE KNOW ACT


KNOW when and how to actACT in your Asset Management tool

Commissioning until nowgAlways on the critical pathManual step-by-step procedureManual, step by step procedureLabor intensiveRequires

Test Report

q– Screw driver– Check sheet– Pencil– Multimeter

O ill– OscilloscopeConnect one device at a timeDisconnect after testing


Disconnect after testing

Simple Commissioning Steps with ADM

Verify address settingWire up devices in the right locationWire up devices in the right locationCheck shieldingActivate communication Test

Report

Use automated work procedures– Testing – Documentation

All devices at onceWi i i di b d!

Commissioning Wizard

Wiring remains undisturbed!


Commissioning Wizard

With Expert System SupportTakes snapshotTakes snapshotIdentifies wiring errosEnsures compliance with AG181 and IEC 61158-2AG181 and IEC 61158-2Recommends limits for ADM messagesStores limits in non-volatile memory

Automatic Tag ReadoutAutomatic Tag ReadoutCreates baseline report:

Snapshot of all measurements C l t d t tiComplete documentation

Saves 80% of pre-commissioning time


Built-in fieldbus oscilloscopeSEE

pADM provides expert tools for fast fault finding

SEE

gFor diagnosing complex scenariosFor the fieldbus expertWith fieldbus specific triggersWith fieldbus specific triggersCaptures up to 10 shots in a row


Online monitoring KNOWgThe Advanced Diagnostic Module:

Monitors physical layer health

KNOW

p y yDetects changing conditionsSends messages with time stamps

Expert System diagnoses faults:Precisely diagnoses causes y gCreates messages with clear textEnables proactive plant up keep Alerts before the segment failsAlerts before the segment fails


Online monitoringKNOW

gClean layout shows boundaries

Displays measurement values

KNOW

p yHighlights violations with color coding: Issues diagnostic messages

Good value

Maintenance required


Out of specification

Diagnostic Menu ACTgExpert System delivers clear text information for fast fault

ACT

finding1 Active messages2 Actionable information with

11

332 Actionable information with solution guideance based on expert system

3 History with timestamps

33

3 History with timestampsWhen the failure…

… occureddisappeared

222

… disappearedExport function for external analysis and storage


The effect of Advanced Diagnostics

Plan and purchase

Install and commission Operate and maintain ACT

TroubleshootMonitorCommission

Longer plant uptimeash

Flow

KNOW

g p p Know before you act Actionable information in clear text

Ca

SEE

Verify against original design Automated checkout procedures


Segment Checker: design of the physical layer

ConclusionFollow proper selection of components, design andinstallation guidelinesinstallation guidelines

System design guideline in AG 181 V3 1 will assist youSystem design guideline in AG 181 V3.1 will assist youto select right components for your NetworkSegment Design tools based on AG 181 V3.1 and IEC61158-2 assist you to design your segmentsAlways use Approved and registered productsRight diagnostic tools helps to reduce installation andRight diagnostic tools helps to reduce installation andcommissioning time


Thank You

Fieldbus FoundationIndia Committee

21st September, 2011


FFIC : Automation 2011 ‐Mumbai

www.fieldbus.org

Documents

FF Physical Layer Components Best PracticesBest Practices · Evolution of Various FF Hazardous Area ... – Screw driver – Check sheet D D – Pencil ... Simple Commissioning Steps