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Installation Technology for Foundation Fieldbus H1 and Profibus PA

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Installation Technology for Foundation Fieldbus H1 and Profibus PA 7/2005 July Automation Technology in Practice Breakthrough in Fieldbus technology – High Power Trunk concepts Reprint Oldenbourg 3 Breakthrough in Fieldbus technology – High Power Trunk concepts Do we see the breakthrough of fieldbus technology in process auto- mation? The fieldbus experience reports presented at the ‘Association of Users of Process Control Technology’ NAMUR general assembly in 2004 seem to confirm that.Topology concepts with high power in the field for all explosion hazardous areas, sophisticated protection and diagnostic functionalities of modern Fieldbus Installation Systems as well as easy-to-use planning tools form the basis for the positive ap- praisal of several major operational process production plants with continuous fieldbus instrumentation.These experiences confirm the expectations specified in 2002 by the FuRIOS study. Introduction in the field, there are I/O inter- faces which convert the digital Nowadays, PROFIBUS and signals of the control system FOUNDATION Fieldbus are fre- into conventional 4-20mA sig- quently discussed in the pro- nals.These may be I/O cards in cess automation industry.Whe- the control room or Remote ther at the NAMUR general as- I/O systems somewhere in the Fig. 1: Fieldbus segment, completely in explosion protection "Intrin- sembly in November 2004, in plant. In any case, there are sically Safe" the discussion forums at the analogue/digital conversions German Interkama fair in April during signal transmission, 2005 or in the many internatio- with all tolerances and risks of Fieldbusses for process au- defines some general conditi- nal brain trusts, plant instru- faults.The core of the current tomation and explosion ons for the structure of a field- mentation with digital commu- discussion is the term "conti- protection concepts bus network.Table 1 summari- nication seems to experience nuous" digital communication, zes the most decisive of these the breakthrough [1]. If approa- i.e. the direct data exchange In fact, the discussed fieldbus- conditions. Furthermore, there ching this topic as an outsider, between the process control ses are the PROFIBUS PA and are four cable types specified this great interest seems astoni- system and the chipset in the the FOUNDATION Fieldbus H1, (table 2).Type A is used as refe- shing at the first sight.The con- field device, without interfaces which both are based on IEC rence cable and is especially re- trol of process plants by means and their tolerances. However, 61158-2 and allow the combi- commended for fieldbus instal- of computer and PLC is a long people want to keep the com- nation of supply current (direct lations.Type C and D should established technology. PROFI- fort of power supply and signal current) and digital signal (al- only be used for modifying BUS DP,HART or similar proto- transmission via the same two- ternating current) on the same existing plants and for heavily cols communicate without core cable, as known from con- two-wire cable.This standard reduced networks [2]. More- problems with the instruments ventional technology. Suddenly close to the processes. the choices are very limited. At least, this seems to be Many of the protocols used in the case. At a closer look, the automation technology, such decisive difference becomes as PROFIBUS DP,Modbus or In- apparent "in the last meters". In dustrial Ethernet, are not desig- most cases, at some point bet- ned for this purpose and requi- ween the digital controllers re additional power connecti- and the sensors and actuators ons. Table 1: Basic fieldbus parameters according to IEC 61158-2 Parameters Specification according to IEC 61185-2 Data transmission rate 31.25 kbps Total length of all cables (cable type A) 1,900 m Max. spur length 120 m Max. number of nodes per segment 32 Signal coding Manchester II Min. operating voltage per device 9 V Min. current consumption per device 10 mA Fig. 2: Fieldbus segment according to the High Power Trunk concept Signal transmission ± 9 mA with fieldbus barriers 4 lows the use of up to eight field sembly in November 2002, devices per segment and consi- marked the turning point.This derably reduces the efforts for study was carried out by Aven- confirmation of intrinsic safety. tis Pharma Germany, now Sa- On the other hand, FISCO speci- nofi Aventis, and Infraserv fies certain cable parameter Höchst Technik with the sup- restrictions which lead to cable port of renowned manufactu- type A as the best choice for Ex rers of process automation ia IIC, increases the technical re- equipment.The basis was the quirements on the field devices newly developed fieldbus bar- and significantly reduces the rier technology, which separa- flexibility of the network. Espe- tes the two functions "fieldbus cially the reduction of the spur power supply" and "protection length to a maximum of 60m by intrinsic safety".This was and the entire cable length to preceded by the consideration 1,000m is quite a setback. For that interventions during live Zone 2, the "Fieldbus Non-In- operation are only necessary cendive Concept" FNICO was at the field devices and their Fig. 3: Fieldbus barriers in the Rubyred plant of Clariant developed and ultimately inclu- connecting leads (spurs), whe- ded in the new edition of IEC reas the passive wiring bet- 60079-27. It considers the lower ween the control room and over, the practical layout of a special precautions.The origi- safety requirements in Zone 2 the distributors in the field is fieldbus network depends on nal approach to fieldbus Ex i and thus allows a higher power subject to minimum stress on- the actual current consumption was a simple transfer of the supply. In all other aspects it ly and thus is hardly affected of the used field devices, the methodology used in conven- corresponds to FISCO with all by faults. Moreover, the com- desired reserves as well as the tional technology by introdu- obvious restrictions. Against munication in the segment ambient conditions. Since the cing special Fieldbus Power this background, it is compre- would be interrupted anyway specification in the standard re- Supplies which meet the requi- hensible that the acceptance of during works on a fieldbus fers to a temperature of 25°C, rements of intrinsic safety.This fieldbus technology in process trunk.Thus, it would hardly be the influences of deviating cli- subjects the complete fieldbus automation was rather restrai- possible to safely continue the matic conditions must be taken segment to the energy limitati- ned for many years. In particu- production process with se- into consideration.These consi- on, as shown in fig. 1.The ana- lar, since the investment costs veral instruments out of ope- derations show that the design logous adoption of the confir- did not bear comparison with ration.The result of these con- of a fieldbus network is a very mation of intrinsic safety, the the established conventional siderations is the use of two complex task, even in the safe so-called Entity concept, did technology due to the low different explosion protection area. Additionally, there are the not only cause a considerable number of fieldbus devices per methods, as shown in fig. 2. safety evaluations when loo- workload in terms of calculati- segment. The trunk between the safe king into explosion hazardous on and documentation, it also area and the fieldbus distribu- areas. For Zone 1, usually the led to the result that only 4-5 Breakthrough in connecti- tors close to the process is in- protection method "intrinsic instruments could be operated on technology – Fieldbus stalled using the explosion safety" Ex i is required because per segment. A different ap- Barriers protection method "increased it is the only method that al- proach, the "Fieldbus Intrinsi- safety" Ex e and thus allows a lows live maintenance and ser- cally Safe Concept" FISCO [3], The FuRIOS study [4], presen- significantly higher supply vice during operation without specified in IEC 60079-27, al- ted at the NAMUR general as- energy compared to Ex i as well as the use of cost-effecti- ve non-Ex power supplies. Fieldbus barriers such as the Breakthrough in Connection Technology: Fieldbus Barriers FieldConnex® FieldBarrier by Pepperl+Fuchs, which allow Profibus DP the intrinsically safe connecti- on of up to four field devices, Segment are used as distributors in Zo- Coupler ne 1. Devices according to En- Termination tity or FISCO can be combined at will since the confirmation of intrinsic safety is only requi- Fieldbus barrier Fieldbus barrier Fieldbus barrier red for the loop between the device and the output of the FieldBarrier. By daisy-chaining multiple fieldbus barriers it is possible now to connect the maximum number of 32 devi- ces as specified in the stan- dard, even in Zone 1 applicati- ons. Further advantages of the FieldBarrier include the indivi- Fig. 4: Conclusion of the fieldbus experience reports at the NAMUR general assembly 2004 dual short-circuit current limi- 5 Table 2: Cable types for fieldbus networks Type A Type B Type C Type D (reference) (*) (*) Cable description Twisted pair, One or more twisted Several twisted pairs, Several non-twisted shielded pairs, total shielding not shielded pairs, not shielded Nominal conductor cross-section 0.8 mm2 0.32 mm2 0.13 mm2 1.25 mm2 (AWG 18) (AWG 22) (AWG 26) (AWG 16) Max. DC loop resistance 44 Ohm/km 112 Ohm/km 264 Ohm/km 40 Ohm/km Characteristic impedance at 31.25 kHz 100 Ohm + 20 % 100 Ohm + 30 % ** ** Max. attenuation at 39 kHz 3 dB/km 5 dB/km 8 dB/km 8 dB/km Max. capacitive unbalance 2 nF/km 2 nF/km ** ** Group delay distortion (7.9 ... 39 kHz) 1.7 mysec/km ** ** ** Surface covered by shield 90% ** n.a.
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