PROFIBUS Installation Guidelines Revision 13.0 October 2016 Verwer Training & Consultancy Ltd Contact information: Verwer Training & Consultancy Ltd 5 Barclay Road, Poynton, Stockport Cheshire SK12 1YY web: www.VerwerTraining.com email: [email protected] tel: +44(0)1625 871199 Copyright Verwer Training Consultancy Ltd, 2008-16 Table of Contents 1. PREFACE ................................................................................................................ 3 2. INTRODUCTION TO FIELDBUS AND PROFIBUS......................................... 3 2.1. PROFIBUS DEVELOPMENT AND HISTORY .............................................................. 4 2.2. THE PROFIBUS FAMILY ........................................................................................ 5 PROFIBUS FMS - Fieldbus Message Specification ..................................................... 5 PROFIBUS DP - Decentralised Periphery................................................................... 5 PROFIBUS PA - Process Automation .......................................................................... 5 PROFINET .................................................................................................................... 6 The control system hierarchy ........................................................................................ 6 2.3. THE OSI MODEL ...................................................................................................... 8 Layer 1 – The physical layer ......................................................................................... 8 Layer 2 – The data link layer ........................................................................................ 8 Layer 7 – The application layer .................................................................................... 8 3. BASIC PROFIBUS NETWORKS ......................................................................... 9 3.1. DEVICE TYPES ....................................................................................................... 10 3.2. NETWORKS AND SEGMENTS ................................................................................... 10 3.3. ADDRESSING ......................................................................................................... 11 3.4. PROFIBUS DATA RATES ...................................................................................... 11 4. PROFIBUS NETWORK OPERATION ............................................................. 12 4.1. TOKEN PASSING ..................................................................................................... 12 4.2. PLC PROGRAMMING .............................................................................................. 13 4.3. NETWORK CONFIGURATION ................................................................................... 14 GSD files ..................................................................................................................... 14 4.4. BUS START -UP ....................................................................................................... 15 4.5. DATA EXCHANGE .................................................................................................. 16 The watchdog timer..................................................................................................... 16 5. PROFIBUS PA ....................................................................................................... 16 6. PROFIBUS INSTALLATION ............................................................................. 18 6.1. PICK -UP IN FIELDBUS CABLES ................................................................................ 18 Electrostatic pick-up ................................................................................................... 18 Electromagnetic pick-up ............................................................................................. 18 Pick-up reduction ........................................................................................................ 19 6.2. PROFIBUS CONNECTION TECHNOLOGY ............................................................... 20 Balanced and unbalanced transmission ..................................................................... 20 6.3. RS485 RULES ........................................................................................................ 22 RS485 segmentation .................................................................................................... 22 Segment length considerations ................................................................................... 23 RS485 repeater limits .................................................................................................. 23 6.4. FIBRE -OPTIC TRANSMISSION .................................................................................. 23 6.5. MBP TRANSMISSION ............................................................................................. 24 7. DEVICE ADDRESSING ...................................................................................... 24 7.1. SETTING ADDRESSES ............................................................................................. 24 Physical address switch on the device ........................................................................ 24 Software setting of device address over PROFIBUS .................................................. 25 Special software and communication link .................................................................. 25 7.2. SETTING AN ADDRESS ON A BINARY SWITCH ......................................................... 25 7.3. RESERVED ADDRESSES .......................................................................................... 25 Installation Guide V13.0 Page i Copyright © Verwer Training & Consultancy Ltd, 2008 - 16 8. PROFIBUS RS485 WIRING ................................................................................ 26 8.1. DP CONNECTORS ................................................................................................... 26 8.2. REFLECTIONS AND TERMINATION .......................................................................... 27 The RS484 termination rules ...................................................................................... 29 8.3. SPUR LINES ............................................................................................................ 30 8.4. PROFIBUS RS485 CONNECTORS AND WIRING TOOLS .......................................... 31 8.5. PIGGY -BACK SOCKETS ........................................................................................... 34 8.6. COMMON RS485 WIRING ERRORS ......................................................................... 34 9. HAND-HELD CABLE TEST TOOLS ................................................................ 35 9.1. WIRING TESTING USING THE BT200 ...................................................................... 35 Basic cable testing ...................................................................................................... 35 Use of the BT200 keypad and display ......................................................................... 36 Wiring testing using the COMSOFT NetTEST II ........................................................ 37 10. LAYOUT OF DP SEGMENTS ............................................................................ 37 10.1. IDEAL SEGMENT LAYOUT ................................................................................... 38 10.2. NETWORK LAYOUT WITH REPEATERS AND OLM S.............................................. 40 10.3. M12 CONNECTOR SYSTEMS ................................................................................ 41 10.4. WHEN ARE SPUR LINES ALLOWED ? .................................................................... 43 10.5. SPECIAL REQUIREMENTS FOR BIT RATES >1.5 MBIT /S ........................................ 45 11. LAYOUT OF PA SEGMENTS ............................................................................ 45 11.1. COUPLER AND LINK TECHNOLOGY ..................................................................... 45 Simple DP/PA couplers............................................................................................... 46 Siemens DP/PA link module ....................................................................................... 46 Higher speed transparent couplers ............................................................................. 47 11.2. MBP SPUR LINES ................................................................................................ 47 11.3. MBP TERMINATION ........................................................................................... 47 11.4. INTRINSIC SAFETY CONSIDERATIONS .................................................................. 49 12. CABLES FOR PROFIBUS................................................................................... 50 12.1. CABLES FOR PROFIBUS RS485 (DP) ............................................................... 50 12.2. CABLES FOR PROFIBUS MBP (PA) ................................................................. 50 13. INSTALLING PROFIBUS CABLES .................................................................. 51 13.1. GENERAL GUIDELINES ........................................................................................ 51 13.2. JOINING CABLES ................................................................................................. 51 13.3. CABLE SEGREGATION ........................................................................................