FF Physical Layer Components

Name Chakravarthy Akella

Bangalore
Job Title Dy. Manager S&S
Company Pepperl+Fuchs
 Agenda

- Introduction

- FF Basics

- FF Zone1 and Zone2 Topologies

- System commissioning and maintenance

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1994 2011 Fieldbus Foundation
 Conventional Instrumentation
4-20mA technique:

Factory
level Ethernet/TCP/IP Work Internet/Intranet
station
Management PC/VME

Cell- Ethernet TCP/IP

level

Operations Maintenance

Ex
Field-
level

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 Fieldbus Instrumentation

Factory
level
Ethernet/TCP/IP Work Internet/Intranet
station
Management PC/VME

Cell-
level Ethernet TCP/IP

Operations Maintenance

Field-
level
Fieldbus Fieldbus EX

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 Expanded View of Process & Instruments
1. Self Diagnostics and communication capabilities of microprocessor based
fieldbus devices helps reduce downtime and improve plant safety.
2. Plant operation and Maintenance personnel can be notified and corrective
actions taken quickly and safely.

Control System Network Control System Network

Analog Controller Fieldbus Controller

PV
PV , Mode , Variables , Alarm
Diagnostics , Etc
4-20mA I/O Subsystem
H1

Traditional 4-20mA View stops at I/O Subsystem Fieldbus Extends View to Field Instrument

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 FF Design Guides
International Codes and Standards
International Electro technical Commission (IEC)

IEC 61158-1 Introductory Guide

IEC 61158-2 Physical Layer Specification and Service Definition
IEC 61158-3 Data Link Layer (DLL) Service Definition
IEC 61158-4 Data Link Layer (DLL) Protocol Specification
IEC 61158-5 Application Layer Service Specification
IEC 61158-6 Application Layer Protocol Specification
IEC 61158-7 System Management
IEC 61158-8 Conformance Testing
IEC 600079-11 (IEC 60079-27) Fieldbus Intrinsically Safe Concept (FISCO)

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 Foundation Fieldbus Design Guides

Foundation Fieldbus compliance Specification

www.fieldbus.org

FF-569 Host Interoperability Support Test

FF-831 Fieldbus Specification for Power Supplies and Conditioners

FF-844 Fieldbus Specification for Cable

FF 846-1.1 Fieldbus Device Couplers used at Zone2 and Zone1

AG 181 System Engineering Guidelines (Rev 3.1)

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 Fieldbus Physical Layer Design Guides

FF has the physical layer specification as per IEC 61158-2:

Transmission rate of 31.25 kBit/s

Total cable (Trunk + Spurs) distance of 1900m maximum

Maximum spur length 120 m upto 12 devices

Up to 32 devices per segment (Host + 31 field)

Manchester II coding used to transmit data

Data transmission by a 9mA modulation signal

Minimum working voltage 9 Volts ( Range is 9-32V) and average current

consumption 20mA per device

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 Output Cable Length

No. of communication elements Max. spur output cable length

1 12 120m
13 14 90m
15 18 60m
19 24 30m
25 32 1m

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 Where is Exe protection required at the
Process Field

Field Enclosure mounted at Zone2, and Zone1

-Mechanical Impact test

-IPrating
-Material Grade
-Drop test
-Vibration test

Any Fieldbus cable system installed at Zone2, Zone1

- IS cables ( for operational reasons)

- non-IS cables
- Armor or conduit wiring are common practice

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 Application - Zone1 installations
Non-IS(EEx e)
Trunk and spurs must be installed in increased safety EEx e

IS ( Limted Power and High Power)

Limited power
ENTITY and FISCO concepts

High Power
HPT
Trunk has to be installed in increased safety
Spurs are intrinsically safe
Allows the use of Non IS Power Supplies and IS FieldBarrier
HPT-IS
Trunk and Spurs are IS

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 Application Area - Zone 1 (EEx d)

Fieldbus Segment Protector Ex me

Power Hub

Ex e

16..32V

230VAC 16..32V

Instruments
Zone 1 Ex d
Live Disconnect Switch
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 User Benefit : Design guidelines

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 IS Fieldbus
Refer AG 181-3.1
-Limited Power
-High Power

High power ( Exe + IS )

High Power IS
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 Application Area - Zone1 IS ENTITY

ENTITY FF
Power Supply V = 10.5V
I = 70mA
Zone 0/1

230VAC 20..35V

9V

Trunk cable < 200m 23mA ENTITY Device

Number of devices less than 2
No load sharing Redundancy at Power Supply

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 Application Area - Zone1 IS FISCO

FISCO FF Power V = 12.5V

Supply
I = 100mA(IIC)
I = 245mA (IIB)
Zone 0/1

230VAC 20..35V

9V

Trunk cable < 400m 23mA FISCO Device

Number of devices less than 5
No load sharing Redundancy at Power Supply

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 Can FISCO/ENTITY power supply be Redundant?

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 Standby FISCO Concept

FISCO FF Power
Supply

Zone 0/1
A

9V
Trunk cable < 400m
23mA FISCO Device
Number of devices less than 5
No load sharing Redundancy at Power Supply
Same limitations as per FISCO concept
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 Application Area - Zone1 IS - HPT

Exd Trunk live disconnect switch

FieldBarrier

Fieldbus
Power Hub
Zone 1

Ex e

Ex ia
(FISCO + Entity)

16..32V

Zone 0/1
230VAC 16..32V

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 Application Area - Zone1 IS HPT
High power trunk or FieldBarrier concept

Trunk is Ex e( increased safety) and Spurs intrinsically safe

Spurs as per FISCO or Entity IS

Longest cable run possible 1900m(Trunk+Spurs) and 120m Spur

No limitation of voltage and current on trunk

Redundant power supplies possible

Trunk could be live disconnect with approved Exd Switch

Hazardous area application with the least difficulties

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 DART Application : IS Fieldbus

The first step

Simplifying
validation

MAX power + FISCO

High Power Trunk Intrinsic Safety

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 Simple DART circuit

Ex ib IIC

Time to turn-off: 510 s

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 Typical Spark Physics

Initial
Critical Phase
Phase
U

IF Spark voltage

di/dt UF

Spark current

PF

Spark duration tF: 5 s2 ms t

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 Typical Spark Turned Off by DART
U, I, P

Initial
Critical Phase
Phase
IF

UF

PF
t
Spark duration with DART tF 5 s

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 DART High Power Intrinsic safety

Provides 850 W, intrinsically safe

Detects sparks as they occur

Limits the energy during a fault

Could be used at Conventional(50W) and Fieldbus(8W)

Applications

A completely intrinsically safe fieldbus segment in

gas groups IIB and IIC with real power redundancy and advanced
diagnostics.

The Intrinsically Safe High-Power Trunk

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 DART (HPT-IS) FIELDBUS STRUCTURE

DCS

Intrinsically Safe IS Segment Protector

Trunk up to 1000m Zone 1/ Zone2

22.5V Each Spur upto

120m
360mA
-------

Upto 16 IS devices

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 Fieldbus Design and validation
Factory Acceptance Tests
Termination
Communication
Parameter measurements
Segment operation all typical segments

Site Acceptance Tests

Network validation
Noise Watch out for Frequency Drives
Electrical characteristics
Grounding and shielding
System Functional Tests
Cable check
Device parameters measurements
Signal patterns etc

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 Commissioning until now

Always on the critical path

Manual, step-by-step procedure
Labor intensive Test Report

Requires

Screw driver
Check sheet
Pencil
Multimeter - FF testers
Oscilloscope
Connect one device at a time
Disconnect after testing

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 Integrated and Portable Advanced Diagnostics

Stand Alone

Integrated at Fieldbus Supply

Portable Advanced Diagnostics
Advanced Diagnostics

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 Maintenance View

Network view

FF-Host

FF-Segment

Segment-specific status of the physical layer

ADM status view with PRM TAG

Alarm window view

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 Simple Commissioning Steps with ADM

x
Verify address setting
Wire up devices in the right location
Check shielding Test
Report

Activate communication

Use automated work procedures

Testing
Documentation
All devices at once Commissioning Wizard
Wiring remains undisturbed!

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 Commissioning Wizard

With Expert System Support

Takes snapshot
Identifies wiring erros
Ensures compliance with
AG181 and IEC 61158-2
Recommends limits for ADM messages
Stores limits in non-volatile memory
Automatic Tag Readout
Creates baseline report:
Snapshot of all measurements
Complete documentation

Saves 80% of pre-commissioning time

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 Diagnostic Menu

Expert System delivers clear text

information for fast fault finding
1
1 Active messages
2 Actionable information with 3
solution guideance based on
expert system
3 History with timestamps
When the failure
2
2
occured
disappeared
Export function for external
analysis and storage

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 Online monitoring

Clean layout shows boundaries

Displays measurement values
Highlights violations with color coding:
Issues diagnostic messages

Good value

Maintenance required

Out of specification

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 Online trending and history

Monitoring
Reveals long term changes
Exports into many formats

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 Built-in fieldbus oscilloscope

ADM provides expert tools

for fast fault finding
For diagnosing complex scenarios
For the fieldbus expert
With fieldbus specific triggers
Captures up to 10 shots in a row

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 Questions

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 THANK YOU

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