Cooper Industries/MTL Confidential
Foundation Fieldbus H1 Introduction
Taking fieldbus H1 into Hazardous Areas
Cooper Industries/MTL Confidential
How is fieldbus different from 4-20mA?
4-20mA
Power
Supply
fieldbus
PowerSupply
– In a Fieldbus system, the power supply, field devices and input card are connected in parallel.
– In 4-20mA circuits, the power supply, field device and input card are connected in series.
Input card
Cooper Industries/MTL Confidential
Expanded System View
FCS: Expanded view. Field
devices are part of the system.
DCS: Limited system view. Does
not include diagnostics and other
information from field devices.
15.3 mA
TAG = LIC-012
VALUE = 70.34
UNITS = m3
STATUS = GOOD
ALARM = Y/N
Cooper Industries/MTL Confidential
Advantages of fieldbus over 4-20mA
Measurement accuracy• Process variable is converted to digital value in the field
device
• Value cannot be corrupted by leakage or electrical interference
• Allows „tighter‟ control of process
Better diagnostic information• Field device diagnostics result in maintenance savings
• No „in range‟ errors
Fewer wire terminations
Cable savings• Multicore „home run‟ cable replaced by single twisted pair
Cooper Industries/MTL Confidential
IEC 61158 Physical Layer
standard
31.25kb/s
Up to 32 devices per
segment - depends on
several factors
Shielded twisted pair - can
use existing field wiring
Power down the bus
Up to 1900 metres with best
cable - more with repeaters
Intrinsically safe
Device connection
Physical Layer - specifications
Cooper Industries/MTL Confidential
Fieldbus in hazardous areas
FIELD
CONTROL ROOM
24Vdc
Control system
FOUNDATION Fieldbus Devices
Wiring
Hub
Trunk
Terminator
Integrated terminator
Power supply & conditioner
(FFPS)
Spur
SEGMENT
Cooper Industries/MTL Confidential
+
-
9-32V100 W
1 mF
SignalIsolationInductors
Near-EndTerminator
100 W
1 mF
Far-EndTerminator
Field Devices
1,900m max.
Power Conditioner
Fieldbus Electrical Circuit Diagram
Power supply, H1 interface card,
field devices and terminators are all
connected in parallel
H1
Interface
Cooper Industries/MTL Confidential
Fieldbus needs terminators
Terminators are required, one at each end, to:
• Provide matched line impedance to minimise reflections &
distortions, and
• Define the impedance of the bus for conversion from current
modulation to voltage modulation*
No more than 2 terminators may be used on one
segment
* FF devices transmit by modulating the current and receive by detecting the modulated voltage
T 100W
1mF
Fieldbus
Host
Control
System
D
T
Cooper Industries/MTL Confidential
Wiring topologies
Point-to-Point
Trunk
Bus with Spurs
Trunk
Daisy-ChainTrunk
“Chicken Foot”
or Tree
JBTrunk
Preferred
Cooper Industries/MTL Confidential
Selection of Power Supplies and
Wiring Components
Taking fieldbus H1 into Hazardous Areas
Cooper Industries/MTL Confidential
Fieldbus in hazardous areas
FIELD
CONTROL ROOM
24Vdc
Control system
Hazardous areaFOUNDATION Fieldbus Devices
Wiring
Hub
Trunk
Terminator
Integrated terminator
Power supply & conditioner
(FFPS)
Spur
?
Hazardous Area
protection
Hazardous Area
protection
?
Cooper Industries/MTL Confidential
Methods of protection
Method of protection Zone 2 Division 2
Zone 1 Division 1
FISCO – Intrinsically Safe
Fieldbus barrier
Ex d/Explosionproof
Ex e/Increased safety
FNICO
Ex nA Non-Arcing
Ex n/Non-incendive
Ex nL
Energy-Limited
Cooper Industries/MTL Confidential
Hazardous area protection
Two End user groups:
• Use intrinsic safety or non-incendive field wiring
• allows live working without gas clearance certificate
• eg. Aramco, BP, Bayer, Chevron, Mol, ONGC
• Use Ex d/explosionproof or non-arcing
• gas clearance certificate required for live working
• eg. Shell, Exxon Mobil
Cooper Industries/MTL Confidential
Live working of field devices
High Energy Trunk
Energy Limited
Trunk
Features No limit on number of devices
Redundant power Limitations on live
working
Limit number of devices
Simplex power Live work trunk and
spurs
Zone 2/Division 2 Non-incendive spurs FNICO
Zone 1 Fieldbus barrier
Zone 22/21 Fieldbus barrier
Division 1 Fieldbus barrier*
FISCO
* Fieldbus barrier is
located in Division 2
Cooper Industries/MTL Confidential
FIELD
CONTROL ROOM
Live-workable Ex nL
spurs
Control system
Ex nL or Intrinsically Safe Fieldbus devices
Zone 2
Division 2
General purpose
Fieldbus power supply
High Energy Ex nA trunk
Spur short-circuit
protection in wiring
hub makes spurs
Ex nL
Non-arcing trunk with Non-incendive spurs
24Vdc24Vdc
Cooper Industries/MTL Confidential
Non-incendive spurs
Field instruments may carry any of the following
approvals:
• Intrinsically safe
• Non-incendive (North America)
• EEx nL (IEC)
Compliance with the following parameters is
required:
• Ui > or = fieldbus power supply max voltage
Recommend Ui > or = 32V
If Ui = 24V use F801 module
If Ui > or = 30V use F802 module
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FIELD
CONTROL ROOM
Ex nA spurs
Control system
Ex n or Ex d/Explosionproof Fieldbus devices
Zone 2
Division 2
High energy Ex nA trunk
Non-arcing trunk and spurs
No live working without power-down
or gas clearance
Fieldbus power
supply
24Vdc24Vdc
Cooper Industries/MTL Confidential
Ex d field devices in Division 1
CONTROL ROOMCONTROL ROOM
Control system
FIELD
Spurs not live-workable
Ex d/explosionproof Fieldbus devices
Zone 1
Division1
High energy Trunk
not live-workable
Junction box:
Ex d/Explosionproof
or Ex e
Fieldbus power
supply24Vdc24Vdc
Cooper Industries/MTL Confidential
Ex e/d field devices in Zone 1
CONTROL ROOMCONTROL ROOM
Control system
FIELD
Spurs not live-workable
Ex d/explosionproof Fieldbus devices Zone 1
Trunk not
live-workable
Junction box:
Ex d/Explosionproof
or Ex e
Field wiring hub
EEx me approved
Fieldbus power
supply
24Vdc24Vdc
Cooper Industries/MTL Confidential
FNICO power supply
FIELD
CONTROL ROOM
Live-workable Ex nL
spurs
Control system
Ex nL or Intrinsically Safe Fieldbus devices
Zone 2
Division 2
24Vdc24Vdc
Live-workable Ex nL trunk
Typical FNICO installation
Cooper Industries/MTL Confidential
FISCO power supply
FIELD
CONTROL ROOM
Live-workable
Ex i spurs
Control system
FISCO fieldbus devices
24Vdc24Vdc
Live-
workable
Ex i trunk
Zone 1
Division 1
GAS DUST
Zone 21
Typical FISCO installation
Cooper Industries/MTL Confidential
Multi-drop capability
Intrinsically safe FISCO Fieldbus devices
Zone 1
Division 1
24Vdc24Vdc
Trunk #2 Trunk #3
Direct
parallel
connection
on safe
area side
Cooper Industries/MTL Confidential
FISCO for hazardous area applications
Intrinsic Safety preferred by many end users for protection of
instrumentation in hazardous areas
• Recognised as „Safest possible technique‟
• Maintenance personnel don‟t need re-training on non-IS techniques
• Field enclosure smaller, lighter and less complex than alternative
techniques using simple wiring hub
Simple safety documentation compared with earlier IS Fieldbus techniques
• Cable parameter calculations –associated with conventional IS circuits – are not needed
Trunk cable lengths and segment loading adequate for many
applications
• Typically 8 devices with 830m trunk cable length in IIB gases
• Typically 5 devices with >640m trunk cable length in IIC gases
Multi-drop capability
Cooper Industries/MTL Confidential
Fieldbus Barrier
Control system
High energy
Ex e trunk
Fieldbus
barrier
Fieldbus power
supply
24Vdc24Vdc
FIELD
CONTROL ROOM
Zone 1
Division 2
GAS DUST
Zone 1/0
Division 1
Zone 21
Zone 21/20
FISCO or entity fieldbus devices
Live-workable
Ex i spurs
Cooper Industries/MTL Confidential
„High Energy Trunk‟ for hazardous areas
25
Benefits of High Energy Trunk concept:
Redundant Fieldbus power supply can be used
Typically 12 instruments (typically limited by cycle time)
Fieldbus trunk is not energy-limited, so very long segment lengths
can be supported
Spurs connect to FISCO or Entity instruments; simple verification
of intrinsic safety
Disadvantages of existing Fieldbus Barrier implementations:
Enclosure involves many components
Solution is customized
Field enclosure is large, complex, expensive
Mix of protection methods within main enclosure compartment
(Ex e trunk and Ex ia spurs) risks maintenance errors
Cooper Industries/MTL Confidential
Maintenance-friendly High-Power
Trunk
Taking fieldbus H1 into Hazardous Areas
Cooper Industries/MTL Confidential
Legacy fieldbus barrier
Designed to provide high levels of energy
in to the field by:
• Using high-power FFPS
• Moving the IS interface into the hazardous area
One Ex e trunk connection per module
Enclosure needs extra terminals for:
• Trunk separation to further barrier modules
• Field device connection
Cooper Industries/MTL Confidential
Legacy Fieldbus barrier
Live-workable
Ex i spurs
Control system
FISCO or entity fieldbus devices
High energy
Ex e trunk
Fieldbus
barrier
Fieldbus power
supply
24Vdc24Vdc
FIELD
CONTROL ROOM
Zone 1
Division 2
GAS DUST
Zone 1/0
Division 1
Zone 21
Zone 21/20
Cooper Industries/MTL Confidential
Custom-designed to suit
project requirements:
• Enclosure material
• Ex-protected isolating switch
option
• Fixed terminator options
• Trunk and spur surge
protection options
• Internal cable management
• Field wiring terminal options
Ex protected
isolating switch
option
Spur surge
protector
option
Additional terminalsTrunk surge protection
and optional combined
fieldbus terminator
Customised FBB enclosure
Cooper Industries/MTL Confidential 30
Connections in customised systems
Number of terminals:
Spur: + / - / Shield of FBB to + / - / Shield of Surge Protector. There are 12 spurs = 72
Spur: + / - / Shield of Surge Protector to + / - / Shield of screw terminal. There are 12 spurs = 72
Trunk: + / - / Shield of FBB to + / - of Ex de switch. There are 3 Trunks = 15
Trunk: + / - of Ex de switch to + / - / Shield of Ex e terminals. There are 3 Trunks = 15
Total = 72 + 72 + 15 + 15 = 174 terminals = 174 potential points of failure!
Cooper Industries/MTL Confidential
12-spur SS enclosure
“Live
pluggable”6-spur Fieldbus
Barrier modules
Spur surge
protector
(optional)
“Live
pluggable”
Terminator
Trunk
terminals
“Live pluggable”
trunk surge
protector
(optional)
Trunk
Terminal
Assembly
(TTA)
housing
Screw-
secured,
pluggable
spur
terminals
Cooper Industries/MTL Confidential
6-spur GRP enclosure
“Live
pluggable”
6-spur Fieldbus
Barrier modules
Spur surge
protector
(optional)
“Live
pluggable”
Terminator
Trunk
terminals
“Live pluggable”
trunk surge
protector
(optional)
Trunk
Terminal
Assembly
(TTA)
housing
Cooper Industries/MTL Confidential
9373-FB Series Fieldbus Barrier enclosure (12 spur)
FIELD
Zone 1
CONTROL ROOM
Increased safety (Ex e)
„High Energy‟ trunk
Fieldbus
Barrier
enclosure
General Purpose
Fieldbus Power
Supply
Intrinsically
Safe spurs
Fieldbus control
system (DCS)
24V dc Bulk power input
Intrinsically safe FISCO or Entity Fieldbus Devices
Cooper Industries/MTL Confidential
Compare size with legacy 12-spur solutions
Existing 12-spur solutions with Surge Protection
9373-FB 12-spur
Fieldbus Barrier
with Spur Surge
Protection
All images approx. to scale
Cooper Industries/MTL Confidential 35
MTL’s 9370-FB is up to 50% smaller than conventional Fieldbus Barrier implementations, leading to significant savings in infrastructure and installation costs
Replace this...
Surely not!
950mm
430mm
.....with this
430mm
Cooper Industries/MTL Confidential
But size doesn‟t matter!
All system components
are pluggable, even in the
hazardous area:
• Safer, easier maintenance
• Allows expansion from 6
to 12 spurs per enclosure*
• Install trunk and/or spur
surge protection modules
during initial installation
or as retro-fit
• Faster fault diagnosis by
substitution
36
Fieldbus Barrier
module
Spur surge
protectors
(one per spur)
Trunk surge
protector
Fieldbus
terminator
* Specify 9374-FB (12-spur) enclosure with 6 spurs
fitted; expand to 12-spurs by addition of second
9377-FB module
Cooper Industries/MTL Confidential
Module carrier
Supplied as part of complete enclosure
assembly
6-spur and 12-spur versions
Provides mechanical and electrical
mounting platform for 9377-FB Fieldbus
Barrier module(s)
Provides pluggable connections to fieldbus
spurs
Robust design
Supports optional Spur Surge Protection
modules
• Integrated high integrity ground connection
37
Cooper Industries/MTL Confidential 38
How are the modules „hot pluggable‟?
Ex de plug/socket system
Patented technology from Cooper Crouse-Hinds
Integrated part of:
• Fieldbus Trunk Terminator
• Trunk Surge Protector
• Fieldbus Barrier Module
Gas tight when inserting (Ex d)
Mechanically designed for Ex e
Allows removal of equipment without
gas clearance or additional Ex de switches
Plug
Socket
Cooper Industries/MTL Confidential
Simplified maintenance
Maintenance
activity
Conventional Fieldbus Barrier
enclosure
9370-FB Series
Fieldbus Barrier
enclosure
Remove and
replace
Fieldbus
Barrier module
• Remove enclosure cover
• Select and operate appropriate
isolating switch
• Open trunk terminal cover on
barrier module
• Remove trunk wiring from
terminals and secure
• Remove spur wiring from
terminals and secure
• Remove and replace barrier
module
• Reinstate trunk and spur wiring
and close trunk terminal cover
• Operate isolating switch
• Replace enclosure cover
• Remove enclosure
cover
• Loosen module
screws
• Remove and replace
barrier module
• Tighten screws
• Replace enclosure
cover
39
Cooper Industries/MTL Confidential
Every module and circuit within the shaded area is live-
workable in the hazardous area
Reducing maintenance risk
Mixing circuits that can be live-disconnected in a hazardous area with those that can’t leads to unnecessary risks during field maintenance – which is
why all circuits and modules.
“I can open the enclosure door of the main compartment and so it only contains IS circuits doesn’t it?”
Cooper Industries/MTL Confidential
Every module and circuit within the shaded area is live-workable
in the hazardous area
Mixing circuits that can be live-disconnected in a hazardous area with those that can’t leads to unnecessary risks during field maintenance – which is
why all circuits and modules in the main enclosure compartment are designed to be replaced while powered.
Reducing maintenance risk
Non-live workable circuits are confined within the Trunk Terminal Assembly compartment and protected by a lockable cover.This only ever needs to be opened during installation and when the trunk cable fails and needs to be swapped over. On both occasions there is no power.
Cooper Industries/MTL Confidential
User-Friendly Handheld, Periodic
Diagnostics
Fieldbus H1 Physical Layer Diagnostics
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Reliability of fieldbus physical layer
At commissioning a few installation
and device faults require correction
After commissioning fieldbus
segments run reliably
• on 300 segment system about one
physical layer problem needs
resolving/year
Relcom fieldbus testers are
estimated to be used on more than
90% of segments installed
Cooper Industries/MTL Confidential
Commissioning Procedure
inspect wiring
unplug power conditioner field
connector
• signal + to signal - >50kohm
• signal + to screen >20Mohm
• signal - to screen >20Mohm
• signal + to ground bar >20Mohm
• signal - ground bar >20Mohm
• screen to ground bar >20Mohm
Cooper Industries/MTL Confidential
Common Faults
Shorts (between +, -, shield, ground)• water
• stray wire strands
• cable damage, etc.
Intermittent connections• broken wires
• improperly connected shield
• loose connector/wire
Terminator• missing/extra/failed
• wrong location
Cable• non compliant
• water ingress
• routed near noisy cable/equipment
• too long
Component failure• Power supply
• Wiring component/terminator
• Field device
Power supply is not isolated
Cooper Industries/MTL Confidential
Characteristics of user-friendly diagnostics
Easy to measure
Easy to understand
Gives definite indication of a problem
Eliminates possible causes
Actionable
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Fieldbus Diagnostic Measurements
Segment Voltage
• Measure voltage on segment
Low Frequency Noise
• Noise measurement at n Hz
In Band Frequency Noise
• Noise measurement at 31 kHz
High Frequency Noise
• Noise measurement at
400kHz
Peak Frequency Noise
• Maximum noise at each of
Low, In Band, and High
frequencies
Live Device Count
• Addition or removal of device
on network
Positive Short to Shield
• Short circuit between these 2
cables
Negative Short to Shield
• Short circuit between these 2
cables
Device Signal Level
• Voltage is between 0.35 and 1
volt
Retransmissions
• Number of messages that
need to be sent more than
once on the network
New Device
• Displayed for 1 hour
Device Removed
• Displayed for 1 hour
Cooper Industries/MTL Confidential
Diagnostics using the FBT-6
Basic failure
alarms
H1 Fieldbus
Plant Resource ManagerTM
(including fieldbus diagnostics)Host control system
Fieldbus power supply
system Field junction boxSegment 1 of 8
FBT-6 Hand-held
Diagnostic Module
I/O &
Controller
Cooper Industries/MTL Confidential
Commissioning Procedure
Connect fieldbus tester at each
field device and at rack room
Save data to FBT-6 memory
Upload fieldbus tester data to
PC via USB
Store segment baseline data
Cooper Industries/MTL Confidential
Typical faults found in commissioning
fieldbus shorts to cable screen due to
poor installation
• fieldbus cable strands shorting to cable shield
Cooper Industries/MTL Confidential
Typical faults found in commissioning
screen grounded at more than one
location when no plant equipotential
ground
• incorrect installation with screen grounded at
devices or in junction boxes
• poor installation practice with loose strands
intermittently connecting to ground
identify by inspection and measuring
groundbar to screen resistance
Cooper Industries/MTL Confidential
Typical faults found in commissioning
insufficiently tightened terminations
faults in physical layer components
• quality issue with batch of knife disconnects
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Typical faults found in operation
water in junction box, cable or device
Cooper Industries/MTL Confidential
Typical faults found in operation
corroded terminals
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Typical faults found in operation
fieldbus short to cable screen
Cooper Industries/MTL Confidential
Typical faults found in operation
electrical noise
• welding cables on fieldbus cable trays
• variable speed drives installed with inadequate
cable grounding
Cooper Industries/MTL Confidential
Typical faults found in operation
faulty fieldbus device
Cooper Industries/MTL Confidential
Periodic monitoring - pros & cons
Advantages
• Low cost
• No false alarms
• Monitor anywhere
Disadvantages
• Data collected manually
• Limited awareness of problems
Cooper Industries/MTL Confidential
User-Friendly Online, Continuous
Diagnostics
Fieldbus H1 Physical Layer Diagnostics
Cooper Industries/MTL Confidential
On-line monitoring
Monitor diagnostic parameters all the time
Diagnostic module attached to the
network
Reports parameters
• using separate bus infrastructure
• using fieldbus
Diagnostic software
• standalone
• integrated in system instrument
management software
Cooper Industries/MTL Confidential
Diagnostics using the FBT-6Diagnostics using the F809F
Basic failure
alarms
H1 Fieldbus
Instrument Management System
(including fieldbus diagnostics)Host control system
Fieldbus power supply
system Field junction boxSegment 1 of 8
FBT-6 Hand-held
Diagnostic Module
On-line
Diagnostic Module
I/O &
Controller
Cooper Industries/MTL Confidential
MTL F809F on-line monitoring
Monitors parameters on 8 fieldbus segments
Reports parameters over fieldbus• ie. It is a fieldbusTM H1 device
No Diagnostic software• Seamlessly integrated into
IMS as FF H1 device
Open solution
• FOUNDATION fieldbusTM H1
device easily integrates with
all DCS
• Full device description
support
F809F
Cooper Industries/MTL Confidential
F809F diagnostic module
Discrete input block
- any parameter in alarm
Resource block
segment transducer blocks
Fieldbus diagnostic
module
Cooper Industries/MTL Confidential
MTL F809F on-line monitoring
Future proof architecture
• Fieldbus DTM support
• Enhanced eDDL support
Minimises total cost of
ownership by integrating
into fieldbus H1 system
• No additional hardware costs
• No additional costs in
installing, commissioning
and maintenance of separate
network
• Instrumentation team use
same software for physical
layer and fieldbus device
diagnostics
Cooper Industries/MTL Confidential
F809F measured parameters
Segment voltage
Average and peak noise• Low frequency band
• FF signalling band
• High frequency band
Fieldbus to shield short circuits• +/- to shield
Device signal voltage• All devices
• Address of device having lowest voltage
Device retransmissions• Address of devices failing to respond to Pass Token
messages from LAS
Address of fieldbus device most recently connected
Number of devices recognised on bus
Address of LAS
Cooper Industries/MTL Confidential
F809F with Honeywell Experion PKS
Up to 10 discrete input blocks can be
configured
Resource block
8 segment transducer blocks
F809F device
systems transducer blocks
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F809F in Yokogawa PRM
Segment noise
Device 1 quality
Cooper Industries/MTL Confidential
F809F in ABB 800xA
Power feed B
low voltage alarm
Power feed B
voltage 0.4V
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F809F trending in Invensys
Trending of
fieldbus segment noise
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Segment alarms in Emerson Delta V
Cooper Industries/MTL Confidential
Troubleshooting questions...
So what does the data all mean?
Is anyone capable of diagnosing the data provided?
What does the scope trace show us?
Does anybody know what jitter is and what it means?
Where do we look next?
Can anybody find the manual?
………?
Cooper Industries/MTL Confidential
Characteristics of user-friendly diagnostics
Easy to measure
Easy to understand
Gives definite indication of a problem
Eliminates possible causes
Actionable
Cooper Industries/MTL Confidential
User-friendly presentation
What we need is:
• Home view for status summary
• Technicians view for current values , alerts
and corrective actions
• Advanced configuration and set up view
Cooper Industries/MTL Confidential
Simple: Home Page
Diagnostic module is a
device on the Fieldbus
port
Home view gives overview about
system (FFPS) and all segments
Cooper Industries/MTL Confidential
Simple: Technicians View
75
Device shows out of
specification alarm.
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Simple: Advanced User
76
The Config/Setup tab allows
to configure warning and
alarm limits for each device.
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The Config/Setup tab
provides a wizard to
optimise alarm limits
Simple: Advanced User
Cooper Industries/MTL Confidential
Open standards: NAMUR NE107
FailureFunction Check
Out of Specification
Maintenance Required
Diagnostic Categories
Cooper Industries/MTL Confidential
Namur NE107
79
Device overview lists all devices
with tag and status.
Only 3 devices on segment, only
3 devices displayed.
Symbols and designations as per
FF-912 and NAMUR NE107.
Cooper Industries/MTL Confidential 80
Device is ok.
Device OK
Cooper Industries/MTL Confidential 81
Device shows needs
maintenance alarm.
Device needs maintenance
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DTM Segment View
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DTM Graphical View
Out of
Specification
Needs
maintenance
Good
Current
value
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Enhanced EDDL
84
System TB block shows
data for power supply
Cooper Industries/MTL Confidential 85
System TB block config
allows to set limits for
fieldbus power supply
Enhanced EDDL
Cooper Industries/MTL Confidential 86
Select which segments
are monitored*
* Segments without field wiring (and hence without second terminator) would give alarm as terminator is missing.
Select segments to be monitored
Cooper Industries/MTL Confidential 87
EDDL can execute methods
(“wizards”)
Alarm optimisation wizard
sets alarms for users set up
FF Methods
Cooper Industries/MTL Confidential88
Device alarm help
Network diagnostic data: DTM
2009 General Assembly
Yokohama, Japan
Troubleshooting guide
Cooper Industries/MTL Confidential
Export Baseline
Cooper Industries/MTL Confidential
Segment Commissioning Report
Namur NE107
status symbols
Alert limitsCurrent values