fieldconnex - connecting fieldbus power and knowledge · cnc pc/vme vme/pc plc pls factory level...

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

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PROCESS FIELD BUS

PEPPERL+FUCHS 3

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


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


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

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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


What about discrete I/O?

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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.

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Fieldbus TopologiesFieldbus Topologies

Junction Box Junction BoxJunction Box

Power Supply / Segment coupler


Junction Box Junction BoxJunction Box

Power Supply/ segment coupler

SegmentProtector

FieldBarrier



Junction Box

Power Supply/ segment coupler

FieldbusProcess

Interfaces

FieldBarrierSegmentProtector


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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


Connecting Fieldbus Power and Knowledge

Robby Bosgaerd

®

PROCESS FIELD BUS

fieldconnex - connecting fieldbus power and knowledge · cnc pc/vme vme/pc plc pls factory level...

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