Fieldbus

Wiring Guide
4th Edition

Relcom Inc.
www.relcominc.com

FieldbusWiringGuide
ThepurposeofthisFieldbusWiringGuideistoprovideinformationabouttheFieldbusinfrastructureso thatitswiringsystemcanbedesignedandinstalledforcosteffectiveandreliableoperation. TherearemanyusesforFieldbusandmanywaysitcanbeconfigured.Itisnotpossibletogivesimple wiringrulesthatcoverallcases.Forthisreason,thisGuidewillfirstexplainhowFieldbusworkssothat thewiringsystemcanbedesignedintelligentlytoachievethebestperformanceandmostreliable operationwiththelowestcost. FieldbusisdefinedinIECstandard611582.Detailedimplementationrequirementsbeyondthe standardareavailablefromtheFieldbusFoundation,anindustryconsortiumthatpromotesFieldbus technology.Thesemoredetailedspecificationsareneededsothatdevicesmadebydifferent manufacturersareinteroperableinacontrolsystem. ThereismoretoFieldbusthanthewiring.ForthosewantinginformationabouthowFieldbusworksto controlaprocess,referto: FieldbusesforProcessControl;JonasBurge,ISBN1556177607 FoundationFieldbus:APocketGuide;IanVerhappenandAugustoPereira;ISBN1556177755. FieldbusFoundation 9005MountainRidgeDrive,BowieBldg,Suite200 Austin,TX787595316,USA Tel:5127948890 www.fieldbus.org RelcomInc. 2221YewStreet ForestGrove,OR97116USA Tel:5033575607 8003823765 Fax:5033570491 www.relcominc.com

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CopyrightandIntellectualPropertyNotices
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TableofContents
Chapter1:FieldbusNetworkConcept..........................................................................................................1 Chapter2:FieldbusConfiguration................................................................................................................3 Chapter3:Signals..........................................................................................................................................5 Chapter4:CableSelection,Installation,andTermination...........................................................................6 CableSelection..........................................................................................................................................6 CableInstallation......................................................................................................................................7 CableTermination.....................................................................................................................................7 Chapter5:Terminator..................................................................................................................................8 Chapter6:ConnectingDevices.....................................................................................................................9 NonIsolatedDeviceCouplers...................................................................................................................9 IsolatedDeviceCouplers.........................................................................................................................11 Chapter7:FieldbusPower..........................................................................................................................12 SelectingaFieldbusPowerSupply..........................................................................................................13 Chapter8:FieldbusSegmentDesign..........................................................................................................14 PowerDistribution..................................................................................................................................14 Distance...................................................................................................................................................14 ControlSystem........................................................................................................................................14 ProcessCriticality....................................................................................................................................15 AreaClassification...................................................................................................................................15 Chapter9:ReliabilityConsiderations..........................................................................................................16 SegmentMonitoring...............................................................................................................................19 Chapter10:HazardousAreas.....................................................................................................................20 DefiningtheHazardousAreas.................................................................................................................20 MethodsofProtection............................................................................................................................21 Division2/Zone2..................................................................................................................................21 Division1/Zone0,1...............................................................................................................................23 Chapter11:FISCO......................................................................................................................................25 WhychooseFISCO?................................................................................................................................26 AssemblingFISCOsegments...................................................................................................................26 Otherdesignconsiderations...................................................................................................................27 RedundantFISCOpowersupplies...........................................................................................................28 Chapter12:CurrentLimiters......................................................................................................................29 Chapter13:Grounding/Earthing................................................................................................................30 Chapter14:PreventingFieldbusPhysicalLayerProblems.........................................................................31 CommonPhysicalLayerProblems..........................................................................................................31 CausesofPhysicalLayerProblems.........................................................................................................31 PreventingPhysicalLayerProblems.......................................................................................................32 Training...................................................................................................................................................32 Supervision..............................................................................................................................................32 Monitoring..............................................................................................................................................33 Tools........................................................................................................................................................33 Examples.................................................................................................................................................35 PreventingPhysicalLayerProblems.......................................................................................................36

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TableofContents Glossary.......................................................................................................................................................37 References..................................................................................................................................................39 ReferenceDocuments ............................................................................................................................39 . CertifiedFoundationFieldbusTrainingCenters.....................................................................................40 Websites ................................................................................................................................................40 . AppendixA:Signals.....................................................................................................................................41 AppendixB:AvailabilityCalculation...........................................................................................................44 AppendixC:FieldbusSegmentDesignCalculation.....................................................................................45

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Chapter1:FieldbusNetworkConcept
Summary:FieldbusisaLocalAreaNetworkforprocesscontrolthatusesasinglewirepairforpowering multipledevicesandcarryingsignalsbetweenthosedevices. Manydifferentfieldbusesarecurrentlyavailable.ThismanualfocusesonFoundationTMFieldbusand ProfibusPA,whichwillbereferencedfromhereonasFieldbus.Bothofthesenetworkssharethesame wiringandpoweringscheme.Theyaresignificantlydifferentinthecommunicationprotocolarea,but thatisoutsidethescopeofthisguide. Inaconventional420mADistributedControlSystem(DCS),twowiresareusedtoconnecttoadevice (normallyusingshieldedtwistedpaircable).Thedevicesmaybeinstrumentsforinputmeasurements suchastemperatureorpressure.Devicescanalsobeoutputssuchasactuatorsandvalves.Thewires carryelectricalpowertoadevice.ThedevicesignalsitsmeasuredvaluetotheDCSscontrollerby varyingthecurrentitusesbetween4and20milliamps(mA).Thecontrollergathersthedatafroma numberofdevicesviathededicatedI/Ocards,makesthenecessarycalculations,andsendscommands byvaryingthecurrenttotheactuatororvalve.Forexample,4mAmaymeanthatthevalveistotally closedand20mAmaymeanthevalveisfullyopen.Thisisreferredtoasananalogsystem,becausethe datatransmittedvariescontinuouslybetween4mAand20mA.

Figure1.1:ConventionalDCS(420mAorHART)

Fieldbusalsousestwowirestocarrypowertothedevices,ascanbeseeninFigure1.2.Forsimplicity thecableshieldisnotshownalthoughitisconsideredrequiredforFieldbus.Anumberofdevices sharethesameFieldbuswires.Fieldbusdevicesvarythecurrentonthetwowirestosendsignals(See Chapter3:Signals).Thesignal(data)isdigital.Thismeansthatthevaluestransmittedarediscrete(not infinitelyvariable).Thisallowsanerrordetectionsystemtobeemployedtoensurethatthereareno errorsinducedbythetransmissionofdatafromthedevice. Becausedevicessharethewires,thedevicescansenddatatoeachotherwithoutaDCScontroller (host).Fieldbusdatatransmissionshavemoreinformationthanjustasinglevariableabout temperature,pressure,orvalveposition.Fromthedatasharedbetweenthedevices,thedevicescanbe configuredtocontroltheprocess.Thehostthenonlysupervisestheoperation.Thisiscalledcontrol inthefield.

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FieldbusNetworkConcept
Fieldbusisalocalareanetwork(LAN)forprocesscontrol.

Figure1.2:Fieldbus(FoundationFieldbusorProfibusPA)

Thetwowiresareatwistedpairsimilartotheusual420mAwiringusedforconventionaldevices.For moreinformation,refertoCableSelection,Installation,andTerminationonpage6. Forthesakeofsimplicityofwiringdiagrams,thewirepairswillbeshownasasinglelineinthe remainderofthisdocument.

Figure1.3:WiringDiagramConvention

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Chapter2:FieldbusConfiguration
Summary:AFieldbussegmentswiringcarriespowertodevicesandsignalsbetweendevices.ADC powersupplyandaFieldbusPowerSupplyareneededtoprovidepowertotheFieldbussegment.Two Terminatorsarerequiredateachendofthesegment. Fieldbusisaprocesscontrollocalareanetworkusedforinterconnectingsensors,actuators,andcontrol devices.AcommontypeofFieldbusconfigurationisshownbelow.

Figure2.1:CommonFieldbusSegmentConfiguration

ATrunkcableconnectscontrolroomequipmentwithanumberofdevicesinthefield(forexample, sensorssuchastemperatureorpressuretransducersandactuatorssuchasvalvepositioners).Multiple fielddevicescanbeconnectedwithSpurcablestoaDeviceCoupler(usuallyinajunctionbox).Thisis calledaChickenfoot,tree,orstartopology.DevicescanalsobeconnectedalongtheTrunkcablewitha singledropDeviceCoupler.Thisiscalledabuswithspurstopology.Multipletopologiesmaybeusedin asinglesegmentalthoughthemostcommonisasingleChickenfoot. ATerminator(T)isrequiredateachendoftheFieldbusTrunkcabletoavoiddistortingsignalsandallow thetwistedpaircabletocarrydigitalsignals.Forconvenience,Terminatorsareoftenincludedin FieldbusPowerSuppliesandDeviceCouplers,eliminatingtheneedforseparateTerminators. PowertothedevicesisprovidedbyaFieldbusPowerSupply.TheFieldbusPowerSupplyisneededto separatethebulkDCpowersupplyfromtheFieldbuswiringsothatthesignalsarenotabsorbedbythe bulkDCpowersupply.TheFieldbusPowerSupplyisnormallyinstallednearthecontrolroombutcould alsobelocatedinthefieldorinamarshallingpanel. ADCSwithanH1interfaceisusuallylocatedinthecontrolroom.Itsfunctionistooverseetheoperation ofthecontrolsystem,madeupofthedevicesconnectedontheFieldbussegment. Often,acompactFieldbussegmentinaboxisneeded.ItcombinestheFieldbusPowerSupply,Device Coupler,andTerminatorsintooneboxandisusedonabenchtoporinthefieldtopowerdevicesfor configurationorvalidation.Figure2.2illustrateshowthisisdone.TheDCPowerSupplyisusuallyawall transformer,butmayalsobeabatterypackforuseinthefieldwhereACpowerisnotreadilyavailable.

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FieldbusConfiguration

Oneormoredevicesmaybeconnectedtotheunit.Aconfigurationdevicethatcanmanipulatethe Fieldbusdevicesisalsoneeded.ThisisusuallyanEmerson375/475orlaptopwithNationalInstruments hardwareandsoftware.

Figure2.2:FieldbussegmentinaboxusingtheRelcomF11PowerHub

OtherFieldbusconfigurationsarepossible.Allconfigurationsrequirebasicsignaltransmissionand powerdistributioncapabilitiesprovidedbyashieldedtwistedpaircable,twoTerminators,anda FieldbusPowerSupply.ThesecomponentsarecollectivelyreferredtoasaFieldbussegment. Althoughthedefineddevicelimitis32,therearegenerallylessthan16devicesonanysingleFieldbus segment.Inalargeprocessplant,theremaybeseveralhundredsegments.Eachsegmentispowered byitsownFieldbusPowerSupply.Thesegmentsarelinkedtogetherinanoverallcontrolsystem throughasoftwareconfigurationwithintheDCSsystemthatisbeyondthescopeofthisGuide. LargeprojectscantakeadvantageofmultipairFieldbuscables.Asinglemultipaircablesupports multipleFieldbusTrunks.Themultipaircableisruntoastrategicallyplacedjunctionbox.Fromthere, theindividualTrunksarethenruntojunctionboxesinthevicinityoftheindividualdevices.ADevice CouplerinthejunctionboxfacilitatesconnectionoftheSpur(s)totheFieldbusdevices.This configurationhelpsreducetheoverallcableinstallationcost.

Figure2.3:MultiplesegmentsinstalledusingMultipaircable

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Chapter3:Signals
Summary:DevicesonaFieldbussegmenttransmitdigitalsignalstoeachotheroverthesamewiresthat powerthedevices.Eachtransmissiononthesegmentisreceivedbyalldevices.Onedeviceonthe segment(theLAS)determineswhichdevicemaytransmitnext. ADCbusvoltage(nominally24Vbutcanbefrom932VDC)issuppliedtothedevicesonthesegmentby theFieldbusPowerSupply.AFieldbusdevicedrawsaconstantamountofcurrentwhennot transmitting.Totransmitinformation,thedevicevariestheamountofcurrentitdrawsfromthe segmenttocreateasignalridingonthe24VDC.DigitaldataissentontheFieldbusatarateof31.25 Kbits/second. Thesignalwaveformisshownbelow.Notethatthesignalisaboveandbelowthe24voltnon transmittinglevelonthesegment.AtypicalFieldbussignalis750mVpeaktopeak,butcanrangefrom 150mVto1000mVpeaktopeak.

Figure3.1:FieldbusSignal

IfanoscilloscopewereusedtoobservethesignalsontheFieldbus,thedisplaywouldshowframeswith gapsofsilencebetweenthem,asshownbelow:

Figure3.2:MultipleFieldbusFrames

HowFieldbusisusedforconveyingspecifictypesofprocessinformationisbeyondthescopeofthis Guide. MoredetailedinformationaboutFieldbussignalingiscontainedinAppendixAonpage41.

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Chapter4:CableSelection,Installation,and Termination
Summary:Fieldbususesshielded,twistedpaircable.ForreliableFieldbussegmentoperation,usecable withtheFoundationFieldbusCheckmark,whichdemonstratescompliancewiththeFF844standard (alsoknownasTypeAFieldbuscable).UseofFoundationFieldbuscheckmarkedcableisalso recommendedforProfibusPA.

CableSelection
Fieldbususestwistedpairwires.Atwistedpairisused,ratherthanapairofparallelwires,toreduce introductionofexternalnoiseontothewires.Ashieldoverthetwistedpairfurtherreducesnoise.The twistedpairwires,theshield,andtheircoveringjacketarecalledacable.

Figure 4.1: Fieldbus Cable (Pencil shown for size comparison)

TheFieldbusFoundationreleasedFieldbuscablespecificationFF844toprovideFieldbususerswith guidanceinselectingcable.Thestandardrequiresrobustcableratedforhightemperaturesandwires thataretinnedtotolerateharshenvironments. ForinstancesinwhichexistingcableisintendedtobereusedforH1communications,itshouldbe thoroughlytestedtoensureitissuitableforusewithFieldbusandingoodcondition. BeyondtheFF844standardrequirements,itisworthconsideringthefollowing: Conformancetoexistingplantstandards,suchasthewireinsulationcolors Roundnessofthecabletogetgoodsealingwithcableglands Easeofremovingthecablesjackettoreducethechanceofcabledamageduringconstruction. Multipaircablesthatcanreduceinstallationcost 16AWGcableisnormallyusedfortheTrunkbecauseitsupportslongerdistances 18AWGiscommonlyusedfortheSpurcablesbecausetheyareshort GoodFieldbuscableiscriticalforreliableoperationoftheplant.Thepriceofgoodcableisrelatively low;thecostofanerraticFieldbussegmentoperationcausedbyuseofsubstandardcableisexpensive. Thecostofreplacingcheapcableisextremelyexpensivebecausenotonlymustthecablebereplaced buttheplantwillalsobeidlewhilethisworkisbeingdone.

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CableSelection,Installation,andTermination

ForalistofFieldbuscableswiththeFoundationcheckmarkgotowww.fieldbus.org.

CableInstallation
CableisthebaseinfrastructureforaFieldbussegment.Deficienciesintheinfrastructurewill causeissueswithcommunication.Theseissuescanbedifficulttopinpointwhenthesystemis upandrunning.Forthisreason,itisextremelyimportanttovalidatethattheinstallationwas doneproperly.Herearesomeimportantthingstowatchfor: Protectfromphysical/environmentaldamage(conduitorcabletray) Ensurethatthecableisnotdamagedduringinstallation Payattentiontothemanufacturersminimumbendradius KeepFieldbus(lowvoltage)cablesseparatedfromhighvoltage(energy)cablessee thetablebelow: Type of Cable Fieldbus Cable 60VDC or 25VAC and < 400VAC > 400VAC Subject to any electromagnetic exposure such as from a VFD (Variable Frequency Drive) Minimum Distance from a Fieldbus Cable 0 inches 4 inches 8 inches 20 inches

Table4.1:Recommendedcableseparationdistances(multileveltray)

CableTermination
Whencableinstallationiscomplete,thenextimportantthingisproperlyterminatingthecable.Justlike propercableinstallation,propercableterminationwillensureareliablesegmentformanyyearsto come.Somethingstoconsiderare: Useagoodcablejacketstrippertomakethisprocessquickwithoutnickingtheconductor jackets. Agoodqualitywirestripperwillremovethewirecoveringwithoutnickingthecopperstrands. Useferrulesonthestrandedwiretopreventstraywirestrandswhichmaylatercauseashort. Useahighqualitycrimpingtoolsizedproperlyfortheferrules. Applypropertorquetoscrewterminalsusingatorquelimitingscrewdriver.Mostpeopleare amazedattheamountoftorqueittakestomeetthescrewterminalmanufactures specifications.Undertorqueingcanlaterresultinalooseconnection. ContactRelcomforrecommendedinstallationtools.

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Chapter5:Terminator
Summary:ATerminatorisneededateachendoftheFieldbussegmentTrunkcable. TwoTerminatorsarerequiredoneachFieldbussegment.Generally,oneTerminatorisatthecontrol roomendofthecableandtheotherTerminatorisinthejunctionboxinthefield. TheTerminatorcanbeaseparatepart,oritmaybepartofaDeviceCoupleroraFieldbusPowerSupply. TheTerminatorshouldbeclearlymarkedsothatitcanbeidentifiedinaninstalledsystem.

Figure5.1:TerminatorExamples

AFieldbussegmentwithouttwoTerminatorswillnothavetheproperlyshapedsignals.Asegmentwith onlyoneTerminatormayappeartofunctionproperly,butwillhavedistortedsignalswithincreased amplitude. AsegmentwiththreeormoreTerminatorswillhavedecreasedsignalamplitude,anddevicesmaylose theabilitytocommunicatewithoneanother.AnextraTerminatorwilltypicallycausea300mVdropin signallevelandamissingTerminatorwillcauseasimilarincrease. 8Doc.No.:501123Rev.:E.0

Chapter6:ConnectingDevices
Summary:FieldbusDeviceCouplersmakewiringeasierandmorereliable.OnlyDeviceCouplerswith theFoundationFieldbusFF846checkmarkshouldbeused.CheckmarkedDeviceCouplersshouldalso beusedforProfibusPA. DeviceCouplersaretheindustrystandardmethodofwiringdevicestoaFieldbussegment.Device Couplersprovideshortcircuitprotectionthatpreventstheentiresegmentfromfailingifonedeviceor Spurcableisshorted. TheFieldbusFoundationcreatedtheFF846standardforDeviceCouplers.DeviceCouplersthatmeet theFF846standardsareawardedacheckmark.CompliancewithFF846ensuresminimumstandards aremetforDeviceCouplerperformance,includinginputimpedance,reactiontimetoashortcircuit, voltagedrop,etc. ThereareseveralwaystoterminatecabletotheDeviceCoupler.Thisincludesscrewterminals, pluggablescrewterminals,andpluggablespringclamps.Atthetimeofthiswriting,themostpopular methodisthepluggablescrewterminal. TwodifferenttypesofDeviceCouplersareavailable:nonisolatedandisolated.

NonIsolatedDeviceCouplers
NonisolatedDeviceCouplersareusedinthemajorityofFieldbusinstallationswhereisolationisnot required.TheseinstallationsaretypicallyclassifiedDivision2,Zone2,ornonhazardous.Isolationmay berequiredforDivision1orZone1,0hazardousareainstallations.SeetheisolatedDeviceCouplers sectionformoreinformation. Figure6.1showstwononisolatedDeviceCouplersandaTerminatorinajunctionbox.Theblack connectorsarefortheTrunkcable. Figure6.2showsthisarrangementschematically.TheTrunkcableisattachedtotheupperlefthand terminalofthe8SpurDeviceCoupler.Theotherendofthe8SpurDeviceCouplerisconnectedtothe 4SpurDeviceCouplerwithashortjumpercable.Theotherendofthe4SpurDeviceCoupleris connectedtotheTerminator,(T).ThegroundconnectionontheTerminatorisforsurgeabatementand isafeatureofthatparticularTerminator(notanessentialpartofaTerminatorsfunction).

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ConnectingDevices

Figure6.1:DeviceCouplerExample

Figure6.2:DeviceCouplerExampleconnectiondiagram

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ConnectingDevices

Thisexampleshowshow12Fieldbusdevicesareinterconnectedinajunctionbox.IfthetwoDevice Couplershadbeenintwoseparatejunctionboxes,thejumpercablewouldsimplybealongercable betweenthejunctionboxes. Usingpluggablescrewterminals,thecablecanbepreparedandattachedtotheplugwithoutreaching intotheoftentightspacesofajunctionbox.TheplugistheninsertedintotheDeviceCouplerand fastenedsothatitdoesnotvibrateoutorbecomedisconnectedifcablesaremoved. DeviceCouplersoftenhaveadditionalfeatures,suchasaDINrailmountingclipandanindicatorlight thatshowsifFieldbuspowerisbeingsuppliedtotheDeviceCoupler.ThebiggestbenefitofDevice Couplersisthattheyhavecurrentlimitersbuiltintothem,whichpreventashortontheSpurconnection frombringingdowntheentiresegment.

Figure6.3:DeviceCouplerShowingCurrentLimiters

IfadeviceortheSpurcableisshorted,thecurrentislimited.TheparticulardeviceontheSpurdoesnot function,butthedevicesontherestoftheFieldbussegmentcontinuetowork.Fortroubleshooting purposes,theDeviceCouplerhasanindicatorlightthatshowstheshortedSpur.Formoreinformation onthistopicrefertoReliabilityConsiderationsonpage16.

IsolatedDeviceCouplers
IsolatedDeviceCouplers(alsoreferredtoasFieldbusbarriers)provideelectricalisolation,voltage limiting,andcurrentlimitingbetweentheTrunkandeachSpur.IsolatedDeviceCouplersaretypically usedinZone1,0,andDivision1hazardousareainstallations.RefertoHazardousAreasonpage20 formoreinformation. OneotherimpactofisolatedDeviceCouplersisthatthedesignmustincludeisolatingcircuitry; therefore,onlinediagnostictoolsinstalledontheTrunkwillnotbeabletoviewand,hence,monitorall thesegmenthealthparametersforeachoftheSpurs. ItshouldalsobenotedthatthecharacteristicsofeachmanufacturersIsolatedDeviceCoupleris different.Toaccuratelydeterminebusconditions,calculationsmustbemadefromthatmanufacturers data/programinsteadofusingagenericsegmentcalculatortool.

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Chapter7:FieldbusPower
Summary:FieldbuscannotbepowereddirectlyfromaDCpowersupply.AFieldbusPowerSupply providestherequiredisolationandpowerconditioningtopoweraFieldbussegment.FieldbusPower SupplieswiththeFoundationFieldbuscheckmarkshouldbeusedforbothFoundationFieldbusand ProfibusPA. FieldbusPowerSupplyrequirementsareidentifiedinFoundationFieldbusspecificationFF831. FieldbusPowerSuppliesthatmeettheserequirementsearntheFoundationFieldbuscheckmark. Checkmarkedpowersuppliesmeetminimumspecificationsfornoise,impedance,jitter,andother importantparameters. TheimportantcomponentsofaFieldbusPowerSupplyareIsolation,PowerConditioning,andCurrent LimitingseeFigure7.1below:

Figure7.1:FieldbusPowerSupply

Isolation
ItiscommonpracticeforBulkDCPowerSupplies(usually24V)tobegroundedinanindustrialplant. Fieldbusisrequiredtobeisolatedfromground(toimprovenoiseimmunity).ThisiswhyFieldbusPower Suppliescontainanisolationstage.

PowerConditioning
AlthoughFieldbusdeviceswillpowerupwithanormalpowersupply,theywillnotsustain communication.ADCpowersupplysjobistoregulatetheoutputvoltage(sayat24VDC).Itdoesitsjob sowellthatitabsorbsanydigitalsignalthatadevicewouldtrytotransmit.APowerConditionerallows powertoflowtotheFieldbus,butblocksthedigitalcommunicationsignalfromflowingtotheIsolator orDCpowersupply.Itslikeaonewayvalve.

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FieldbusPower

CurrentLimiting
AcurrentlimiterisprovidedintheFieldbusPowerSupplytopreventdamagefromashortcircuitor overloadcondition.ThisalsopreventstheFieldbusPowerSupplyfromdemandingtoomuchcurrent fromtheDCpowersupply.

SelectingaFieldbusPowerSupply
AslongasaCheckmarkedFieldbusPowerSupplyisused,thereareonlyfourthingstoconsiderwhen selectingtheexactFieldbusPowerSupplyforaparticularsegment: HazardousArea Voltage Current Redundancy

HazardousArea
Ifanypartofthesegmentgoesintoahazardousarea,theselectionoftheFieldbusPowerSupplymay beaffected.Whetheritisaffectedornotdependsonwhatmethodofprotectionisgoingtobeused. Formoreinformation,seeHazardousAreasonpage20.

Voltage
Fieldbusdevicesrequirebetween9and32VDCtooperate(caution:someFieldbusdevicesrequire morethanthe9VminimumspecifiedbytheFieldbusstandard).Becauselongdistancesareinvolvedin asegmentinstallation,thereisasignificantvoltagedropfromtheFieldbusPowerSupply(normallynear thecontrolroom)totheFieldbusdevices.FieldbusPowerSuppliesareavailablewithvariousoutput voltages,andonemustbechosentosufficientlysupplythefarthestFieldbusdevice.

Current
TheFieldbusPowerSupplymustbeabletosupplyallofthecurrentrequirementsofthesegmentwith somemargintothesupplysratedoutputcurrent.FurtherinformationisavailableintheSegment Monitoringsectiononpage19.

Redundancy
Forinstallationswithhighreliabilityrequirements,redundantFieldbuspowersuppliesaredesirable. Seepage16forfurtherinformationonredundancy.

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Chapter8:FieldbusSegmentDesign
Summary:Power,distance,controlsystem,processcriticality,andareaclassificationlimitthesizeofa Fieldbussegmentandthenumberofdevicesthatcanbeinterconnected.

PowerDistribution
ThenumberofdevicesthatcanbeonaFieldbussegmentislimitedbytheFieldbusPowerSupply voltage,theresistanceofthewiresinthecable,andtheamountofcurrentdrawnbythedevices. Thepowerdistributioncalculationquicklybecomescomplicatedwhenmultipledevicesareattachedto thecableatdifferentplaces. CalculatorsareavailablefromsomeFieldbusPowerSupplymanufacturers,anumberofControlSystem suppliers,andtheFieldbusFoundationformakingtheseFieldbussegmentcalculations.TheFieldbus devicecharacteristics,FieldbusPowerSupply,cabletype,andcablelengthsareenteredintothe calculator.Thecalculatorindicatesifthesegmentdesignisgood,marginalorbadanddisplaysthe voltageateachdevice. SeeAppendixConpage45foranexamplesegmentdesigncalculation.

Distance
TheFieldbusstandardidentifiesdistancelimitationsofFieldbuscables. Thetotallengthofallcablesonthesegment(Trunklength+Spurlengths)mustbelessthan1900m. ThemaximumSpurlengthis120m.Additionallimitationsmayapplybasedonthesegmentshazardous arealocation.

ControlSystem
MostFoundationFieldbuscontrolsystemssupportamaximumof16devicesoneachFieldbusI/O card. ProfibusPAspecifiesalimitof32devicespersegment. Thecontrolsystemisrarelythelimitingfactorwhendeterminingthemaximumnumberofdevicesona segment.

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FieldbusSegmentDesign

ProcessCriticality
Plantsoftenhavedesignrequirementslimitingthenumberofdevicesandcontrolvalvesonanyone segment.Thisusuallydictatesthemaximumnumberofdevicesonthesegment.

AreaClassification
Installationinhazardousareascanalsolimitcablelengthsandthenumberofdevicesonasegment.See HazardousAreasonpage20forfurtherinformationonhazardousarealocationconsiderations.

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Chapter9:ReliabilityConsiderations
Summary:SinceFieldbususessharedwiring,reliabilityprecautionsneedtobetakenforsegmentsused incriticalapplications.ReliabilityenhancementincludesshortcircuitprotectorsonSpurcables, protectedTrunkcable,redundantpowersupplies,andsurgeprotectors.

Figure9.1:Fieldbussegment

ThesharedwiringandtheFieldbusPowerSupplyarecriticalresources,becauseallthedevicessharethe samecableandpowersupply.Ifthesefail,thenthewholesegmentisinoperative.ThemainFieldbus reliabilityissuesare: Spurshortcircuits Trunkfailures Powerfailures Surges Segmentmonitoring

SpurShorts
SinceFieldbuswiringisshared,ashortcircuitinoneofthedevicesorinitsSpurcabledisablesthe segmentandthewholeprocessthatdependsonit.Thiscanhappenwhenanewinstrumentis installed,aninstrumentisserviced,orthedevicebecomeswaterlogged. ThispotentialproblemcanbeovercomebyusingacurrentlimiterbetweentheTrunkcableandthe Spurcable.ThesearebuiltintoaDeviceCoupler.Thecurrentlimiteronlyallowsagivenamountof currenttobeusedbyeachdevice.IfaSpurisshorted,thecurrentwillbelimitedwithinafew microseconds.Onlytheshorteddeviceisaffected;therestofthedevicescontinuetooperate.

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ReliabilityConsiderations

Figure9.2:SpurShortCircuitProtectionwithActiveCurrentLimit

CurrentlimitersarealwayssetatahighervaluethantheFieldbusdevicecurrent.Forthisreason, alwaysaddthecurrentfromoneshortedSpurtothetotalcurrentneededbythesegment.Thisensures thatenoughcurrentisavailabletosupplyalldevicesandthevoltageatthefurthestdeviceisaboveits minimumrequiredvoltage.Manysegmentcalculatorsperformthisfunctionautomatically.

TrunkCableFailures
AnothervulnerabilityofthesystemistheTrunkcable.Ifitiscut,thenthepowertothefieldislost. Whilethisistrue,Trunkcablevulnerabilityissomethingthatisalsoaproblemintraditional420mADCS systemsbecauseoftheuseofmultipaircables. Intheend,ifsystemreliabilityisaconcern,theTrunkcableneedstobeprotectedinaconduitora sturdycabletray.

PowerSupplyFailure
IfFieldbussegmentpowerfails,theentireFieldbussegmentistakendownandcontrolislost. Redundantpowersuppliesmakethispossibilityverysmall. ThecomponentpartsofaredundantFieldbusPowerSupplyareshownbelow.TheFieldbusPower Supplysinputcomesfromtwobatterybackedbulkpowersuppliesthatprovide24Vpowertovarious otherpiecesofequipmentinthecontrolroom.Theinput24VpowerfeedstwoindependentFieldbus PowerSupplies.TheoutputsofthetwoFieldbusPowerSuppliesarecombinedtofeedtheFieldbus segment.

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ReliabilityConsiderations

Figure9.3:RedundantFieldbusPowerSupply

However,redundancyaloneisnotenough.Theremustbealarmingaswell.Withoutalarmingan operatorisunawareofthefirstfailure.Asecondfailurecanthentaketheredundantsystemdown.The alarmingshownabovemonitorstheinputpowerandeachoftheFieldbusPowerSupplies.Thealarm itselfcanbeasimplenormallyclosedrelaycontact.ThisrelayisconnectedtotheDCSandnotifiesthe operatorthatthereisaproblem.Indicatorlightsontheredundantpowersupplyshowmaintenance personnelwhichmoduleofthesupplyisdefective.ThefaultyFieldbusPowerSupplymodulecanbe hotswappedwithnodisruptiontotheoperationoftheFieldbussegment. ThetablebelowshowsanexampleMeanTimetoFailure(MTTF)ofthecomponentsofaredundant FieldbusPowerSupply.

Component Fieldbus Power Supply module Fieldbus Power Supply backplane and alarming circuits leading to failure of Fieldbus segment Mean Time To Failure 54 years 88000 years

Table9.1:RedundantFieldbusPowerSupplyMeanTimetoFailure

AmoreusefulfigureforthecontrolengineeristheAvailabilityofasystem. TheAvailabilityforaFieldbussegmentduetotheredundantFieldbusPowersupplysystemcanbe 99.9999989%orevenhigher.ThismeansthataFieldbussystemcouldbedownduetoredundant powersupplyfailuresonaveragefor0.3seconds/year. FordetailsontheAvailabilitycalculation,seeAppendixBonpage44.

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LightningSurges
Thereisnoprotectionagainstadirectlightningstrike.Theenergyinvolvedistoogreat.Thestruck devicesimplydisintegrates. Lightningstrikesalsohaveeffectsatgreatdistancesfromthestrikepoint.Thevoltagebetweenearth pointsthatarenormallyconsideredatthesamepotentialbecomeslarge.Ifacableconnectsdevices thatareatsomedistancefromeachother,thegroundpotentialdifferencecantraveloverthecableand breakdowntheelectricalisolationofFieldbusdevices.SincemanyFieldbusdevicessharethesame cable,alightningsurgecanadverselyaffectallofthem. Thegeneralruleisthatifthehorizontaldistancebetweendevicesisgreaterthan100morvertical separationgreaterthan10m,lightningsurgeprotectionshouldbeused.GiventhatFieldbusdevicesare unlikelytoallbemountedwithinafewmetersofeachother,thevoltagedevelopedbetweenanytwo devicescouldbelargeenoughtobreakdowninsulationandproducedamage. Installationsmustalsoconsiderthatwiththeincreaseduseofhighvoltage,highfrequencyequipment suchasvariablespeeddrivestherearealsoincreasedrisksofharmonicsandotherinducedvoltagesas sourcesofsurgecurrentsonasegment. ForfurtherinformationonSurgeProtection,seetechnicaldataavailablefrommanufacturersofSurge ProtectionequipmentforFieldbus.NotethatitisimportantthattheSurgeProtectiondevicesare specificallydesignedforFieldbus.

SegmentMonitoring
Anotherwaytoimprovesegmentreliabilityistocontinuouslymonitorthesegmenttogetearlywarning ofpotentialissues.Diagnosticproductsareavailabletomonitor: DCvoltage Devicesignallevels Noiselevels Shortstotheshield Communicationhealth Thisinformationcanbetrackedbytheassetmanagementsystemfortrendanalysis.Withthis information,itispossibletoreducethenumberofunexpectedfailures.

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Chapter10:HazardousAreas
Summary:TherearemanygoodsolutionsforinstallingFieldbusinahazardousarea.Choosingone methodinvolvescompanypolicyandananalysisofthebenefitsandcostsofeachoption.Special installationanddesignpracticesmayneedtobefollowedforthehazardousarea.

DefiningtheHazardousAreas
ThemajorityofhazardousareasinwhichFieldbusisinstalledcontainhazardousgasesthatmaybe presentatdifferentfrequencies(hoursperyear).Ourdiscussionwillfocusonthiscategory.Figure10.1 illustratesthathazardousareasarecategorizedintwodifferentways:Divisionsaretypicallyusedin NorthAmerica,whileZonesareusedintherestoftheworld.

Figure10.1:HazardousAreaClassifications

Definitions:
NormalOperatingConditions Theconditionthattheapparatusisexpectedtooperatein. Thisincludesopens,shorts,andgroundingofanywiring connectedtotheapparatus. Themethodusedtoprotectfromanignitioninahazardous area. Anapparatusoutputorwiringthatdoesnotcontainenough energytocauseanignitionevenifopened,shorted,or grounded. Anapparatusorwiringthatwillnotcauseanignitionunder normaloperatingconditions.Thisdoesnotnecessarilymean itisenergylimited.Ifanapparatusoutputshighenergybutis protectedinsomeway(fromshorts,opens,andgrounding),it

MethodofProtection Energylimited

Nonincendive

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NonincendiveFieldWiring canstillbecallednonincendive. AphraseusedintheU.S.toindicatethattheapparatusoutput orwiringisenergylimitedandwillnotcauseanignitioneven whenopened,shorted,orgrounded. Theapparatusorwiringisnotcapableofgeneratingaspark orhotsurfaceundernormaloperatingconditions.Typically highenergyexiststhatcouldcauseaspark,butsomemethod isbeingusedtoprotectagainstanignition(protectfrom shorts,opens,andgrounding).

NonArcing

MethodsofProtection
WhenplanningtoinstallFieldbusinahazardousarea,thefirstthingthatmustbedeterminedisthe methodthatisbeingusedtoprotectfromanignition(explosion).Themethodchosenmayhavetodo withcompanypolicy,butinmostcasesisafunctionofinstallationcostandoperationalmaintenance. ExplosionProofisamethodthateitherpreventsthegasesfromgettingtotheelectricalenergy,or preventsanignitionfrompropagating(bycontainingitwithintheExplosionProofenclosure).This methodofprotectionmaybeusedinallhazardousareasanddoesnotputanyrestrictiononthe equipmentused.EquipmentonlycertifiedforGeneralPurpose(nonhazardous)installationcanbeused withthismethod.Theremainingmethodsofprotectiondifferdependingonthehazardousarea.The followingwillnowfocusonthetwomainhazardousareas.

Division2/Zone2
MethodofProtection NonArcing HighenergyTrunk FNICO(FISCOic)
Table10.1:Div2/Zone2MethodsofProtection

Trunk NonArcing NonArcing EnergyLimited

Spurs NonArcing EnergyLimited EnergyLimited

NonArcing
ForDiv2/Zone2,anonArcingmethodofprotectionmeansthatthewiringandelectricalapparatusdo notgeneratesparksorhotsurfacesthatcouldcauseanignitionundernormaloperatingconditions.In thiscase,thewiringmustbeadequatelyprotectedtopreventopen,shorts,andgrounding.Ingeneral, thesystemcannotbeworkedonwhilepoweredunlesstheareaissniffedtoensurenohazardous gasesarepresent. Beyondthephysicalprotectionofthewiringanddevices,nootherspecialdesignrequirementsare imposedontheFieldbusequipment.AslongastheequipmentiscertifiedasnonArcing,itcanbe installedasifitwereinanonhazardousarea(subjecttothehazardousareaspecificinstallation requirements).

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HazardousAreas

HighEnergyTrunk(Div2/Zone2)
ThetermHighEnergyTrunkisusedtoindicatethattheTrunkcarriesanincendivelevelofpowerand mustbeprotectedasinthenonArcingcase,buttheSpursareenergylimitedinthiscasebythe DeviceCoupler.

Figure10.1HighEnergyTrunksegment(Div2/Zone2)

ThisisthemostpopularwaytoinstallFieldbusinaDiv2/Zone2hazardousarea.Duetothehigh powerontheTrunk,thenumberofdevicesandlengthofthesegmentarenotlimitedduetobeingin thehazardousarea.CurrentlimitationisprovidedintheDeviceCouplerwhichlimitstheenergyonthe SpurandtotheFieldbusdevice.TheSpursmaythenbeworkedonwhilepowerisappliedwithout gettingagasclearancepermit(subjecttolocalcodes).SincetheTrunkishighenergy,itiscommonfor theseinstallationstouseRedundantFieldbusPowerSuppliesforhighreliability. RefertoCurrentLimitersforNonIncendiveProtectiononpage29formoredetailsaboutusingthis methodofprotection.

FNICO(FISCOic)
FNICOstandsforFieldbusNonIncendiveCOncept.ItistheZone2versionofFISCO(Fieldbus IntrinsicallySafeCOncept).Recently,thestandardshavechangedandaddedaZone2specificationto FISCO,calledFISCOic.Eventually,thetermFNICOwilldisappear. FNICOhereimpliesthattheFieldbusPowerSupplyiscertifiedasaFNICO(orFISCOic)device.Assuch, itsoutputislimitedinenergysuchthatashort,open,orgroundingofthewiringwillnotcausean ignitioninthepresenceofhazardousgases.So,inthiscase,theentiresegment(fromtheFNICOsupply uptoandincludingtheFieldbusDevices)isenergylimited.Thishastheadvantageofbeingabletolive worktheentiresystem.Thedisadvantageisthat,becauseofthelimitedenergy,thecablelengthwillbe shorterthanthepreviousmethodsdiscussed,andthenumberofFieldbusdevicesonthesegmentwill beless.

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HazardousAreas

Division1/Zone0,1
MethodofProtection IncreasedSafety HighenergyTrunk FISCO
Table10.2:Div1/Zone0,1MethodsofProtection

Trunk NonArcing NonArcing IntrinsicallySafe

Spurs NonArcing IntrinsicallySafe IntrinsicallySafe

IncreasedSafety
IncreasedSafetyisanonArcingtechniqueforZone1.SincegasesaremorelikelytobepresentinZone 1thaninZone2,therequirementsontheequipmentcertifiedandinstalledunderIncreasedSafetyare highertoreducetheprobabilityofanignition.Notethatthismethodofprotectionisnotavailablefor Divisions. DetailsofanIncreasedSafetyinstallationarebeyondthescopeofthisguide.However,asinDiv2/ Zone2nonArcing,aslongasthecertificationrequirementsaremet,theFieldbussegmentisinstalledas ifitwerenonhazardousinotherwords,withlotsofpower,cablelength,andFieldbusdevices.

HighEnergyTrunk(FieldbusBarriers)
InsimilarfashionforDiv2/Zone2,HighEnergyTrunkforZone1hasanincendiveleveltrunkwhichis usuallyinstalledusingIncreasedSafetytechniques.ThesegmentthencontainsanIsolatedDevice Coupler,morecommonlycalledaFieldbusBarrier,inthefieldtoseparatetheTrunkfromtheSpurs. TheSpursarethenIntrinsicallySafe(entityorFISCO). AFieldbusbarrierusesacombinationofnonArcingandFISCOtechniquestoallowFieldbusdevicesto workinahazardousarea.ATrunkcablegoingthroughaDiv1orZone1areacarriesFieldbuspower betweenaFieldbusPowerSupplyinthecontrolcentertotheFieldbusbarrier.SincetheTrunkishigh energy,itispossibletouseRedundantFieldbusPowerSupplieswithFieldbusbarriers. ThefunctionoftheFieldbusbarrieristoprovidegalvanicisolationbetweentheTrunkcableandthe Spurcables.ItalsoreducesthevoltagetoeachSpurtoanacceptablevalueandlimitsthecurrentto eachdevice.TheFieldbusbarrieralsoprovidesawayforsignalstotravelbetweentheTrunkandthe Spurs. ThediagrambelowshowsthegeneralFieldbusbarrierarrangement.AFieldbusbarriergenerallyserves fourtosixFieldbusdevices.MultipleFieldbusbarriersmaybeonthesameTrunkcable.

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HazardousAreas

Figure10.2HighEnergyTrunk(Div1/Zone1)

TheFieldbusdevicesandtheSpurcablesmaybeworkedwithoutdeterminingiftheareawheretheyare locatedissafe(subjecttolocalcodes).TheTrunkcable,however,cannotbeliveworked,andthearea mustbedeterminedtobesafebeforeanyworkisdone. ItisimportanttorememberthatsincetheFieldbusbarriercontainsactivecomponents,therequired inputvoltageatthebarrierwillneedtobegreaterthan9volts.Inaddition,becauseeach manufacturersFieldbusbarrierhasuniquecharacteristics,aSegmentCalculatortoolprovidedbythat manufacturerMUSTbeusedwhendesigningthesegment.

FISCO
FISCOstandsforFieldbusIntrinsicallySafeCOncept.Pleaseseechapter11fordetailedinformationon FISCO. TheconcepthereissimilartoFNICOexceptinDiv1/Zone1areas,energylimitedmeansIntrinsically Safe.EnergyislimitedtoalowerlevelthanFNICO.So,likeFNICO,boththeTrunkandSpursare protectedbyaFISCOFieldbusPowerSupplythatlimitstheenergytomeettheDiv1/Zone1 requirements.Thismeansthatcablelengthandnumberofdevicesonthesegmentisfurtherreduced fromFNICOlevels.However,theadvantageisthattheentiresegment(beyondtheFISCOsupply)may beliveworked.Recently,aRedundantFISCOSupplyhasbeendevelopedtoimprovesystemavailability.

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Chapter11:FISCO
TheFieldbusIntrinsicallySafeCOncept(FISCO)istheresultofexperimentalworkthatwaspromptedby practicallimitationsoftheoriginalFF816Entityconceptfor31.25kbits/sintrinsicallysafe(IS)bus networks.Thisresearchshowedthat,providedtheinductanceandcapacitanceperunitlengthoffield cablesarekeptwithindefinedlimits,theriskofsparkignitiondoesnotincreasewiththetotallength. ThesefindingshavebeenusedtosimplifythedesignanddocumentationofISFieldbusandtosupport moreFieldbusdeviceswithgreatercablelengthsthanwaspossibleundertheEntitymodel.To assembleaFISCOFieldbussystem,theFISCOFieldbusPowerSupply,fielddevices,cables,andwiring componentsneedtocomplywithFISCOdesignrules,asdefinedinIECstandard6007927. AtypicalFISCOsystemincludesapowersupplyandconditioner(containingtheISbarrier)toprovide powertothebus,andcertifiedwiringcomponentstomakeconnectionsbetweentheTrunkandSpur cables.Figure11.1showsatypicalarrangement.

Figure11.1:TypicalFISCOsegment

FISCOstrengthensthecaseforafullyISapproachbyincreasingtheavailablecurrentand,hence,the numberoffielddevicesthatcanbesupported.Itthereforedeliversanumberofbenefitsoverthe earlierEntitymodelforIntrinsicallySafefieldbus:

Theeliminationofcableparametercalculationsthroughoutthewholesegment,includingTrunk andSpurs.Thismeansthatmodifications,suchastheadditionofafielddevice,maybe undertakenwithoutreassessingthewholecombinationofdevicesandinterconnectingcable. TheopportunitytoprovidehigherlevelsofoutputcurrentinIECGroupIIB/NorthAmericanC, DgasgroupsthataremorecommonlyoccurringthanIIC/GroupsA,B.PracticalFISCOpower suppliesforIIB/GroupsC,Dhaveanoutputvoltageof13.1Vandamaximumcurrentashighas 265mA.

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FISCO

WhychooseFISCO?
UserswhohaveselectedFISCOhavedonesoforoneormoreofthefollowingreasons: 1. Internationallyrecognized TheIEC6007927standardthatdefinestherulesforselecting,installingandmaintainingFISCO apparatusisinternationallyrecognizedandadoptedintothenationalstandardssystemsof manycountriesworldwide.TheFISCOstandardisalsorecognizedbytheFieldbusFoundation andiscomprehensivelysupportedintheFoundationsapplicationguides,suchasAG163(for 31.25kbits/sIntrinsicallySafeSystems).

2. Familiar,established,safe TheentirefieldsegmentofaFISCOinstallationincludingTrunkandSpursisintrinsicallysafe, meaningthatconventionalISmaintenancepracticecanbeapplieduniversally.Thismaybe especiallyimportantforenduserswhoaremakingthetransitionfromconventionalpointto pointwiringtoFieldbus,andwhowishtotransferfamiliarandestablishedISpracticewithout theneedforretrainingofinstrumenttechnicians.Intrinsicsafetyisalsowelldocumentedin theinstallationcodesofallindustrializednations,andbenefitsfromclearlydefinedrulesforthe openingoffieldenclosuresandmaintenanceofcircuitswhileenergized.

3. Simplerisbetter TheonlyitemrequiredtobeinstalledinthefieldinaFISCOsegmentisanintrinsicallysafe DeviceCouplerorMegablockanditsassociatedenclosure,which,dependingontheapplication, mayaccommodateupto12fielddeviceconnections.

AssemblingFISCOsegments
ToensurecompliancewithFISCO,thepowersupplyandfieldbusinstrumentsmustnotonlybecertified toconventionalISstandards(appropriatetotheZoneorDivisionofuse),buttheymustalsocomply withtheIEC6007927standardandbemarkedFISCO.Furtheranalysisofthesafetyparametersisnot necessary,sincecompatibilityisautomaticallyguaranteedbythecertificationprocess.Thesafety parametersforFISCOpowersuppliesandFieldbusinstrumentsaregiveninTables12.1and12.2, respectively.TheDeviceCouplerandTerminatorsmustalsocarryIScertificationandhaveinputsafety parametersthatarecompatiblewiththeoutputofthesupply.

Maximumoutputvoltage,Uo Maximumoutputcurrent,Io 17.5V 380mA Maximumoutputpower,Po 5.32W (excluding Ex ic power supplies) MaximumunprotectedinternalcapacitanceCi 5nF MaximumunprotectedinternalinductanceLi 10H
Table11.1FISCOsafetyparametersforFieldbusPowerSupplies

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InputvoltageparameterUi

17.5V InputcurrentparameterIi 380mA (excluding Ex ic Field devices) InputcurrentparameterPi 5.32W (excluding Ex ic Field devices) MaximumunprotectedinternalcapacitanceCi 5nF MaximumunprotectedinternalinductanceLi 10H(20HforExic)
Table11.2FISCOsafetyparametersforFieldbusDevices

BecauseFISCOisbasedonexperimentaldata,thetotalcablelengthofthesystemislimitedtoa maximumof1,000minIIC/GroupsA,Bgasesand1,900minIIB/GroupsC,D(limitedbyFF831and thereforeidenticaltoanyFieldbussystem).ThemaximumSpurlengthforanyFISCOinstallationis60m perSpur.Iftheselengthrestrictionsareadheredto,theIEC6007927standardpermitsthecable parametercalculations(normallyassociatedwithIScircuits)tobeomitted.

TheIEC6007927standardalsorequiresthatcablesusedinaFISCOsegmentconformtospecifications forresistance,inductance,andcapacitanceperunitlength.TheseparametersarestatedinTable11.3. TypicalFieldbuscablehasparametersof50ohms/km,0.8mH/km,and120nF/km,sotheselimitsarenot restrictive.Complianceshouldnormallybedemonstratedbyobtainingaspecificationfromthecable manufacturer.However,theparametersarenotrestrictivesincetheyaremetbymostcablesthatare designedspecificallyforFieldbusapplications.Ifexisting,installedcablesaretobeused,orifno specificationisavailablefromthecablemanufacturer,compliancemaybeshownbymeasurement. Loopresistance 15150ohms/km Loopinductance 0.41.0mH/km Loopcapacitance 45200nF/km
Table11.3FISCOCableParameters(fromIEC6007927:2004)

Otherdesignconsiderations
SetagainsttheadvantagesofFISCOarethetechnicalboundariesthatareimposedbydesigningfor intrinsicsafety.Themostsignificantconstraintisthereducedoutputvoltageattheterminalsofthe FISCOpowersupply,whichmustbeconsideredcarefullywhendesigningtheFieldbussegment.

Influenceofoutputvoltageonsegmentlength
TheminimumoutputvoltageofatypicalFISCOpowersupplyforIIC/GroupsA,Bgasesis12.4V,andis 13.1VforIIB/GroupsC,D.FieldbusinstrumentsarerequiredbytheFieldbusFoundationtooperateata minimumof9.0V,andamarginontheoperatingvoltageissometimesapplied.Thepermitteddistance andthenumberofinstrumentssupportedfollowOhmslaw:themoredevices,thegreaterthetotal currentconsumptionandthehigherthevoltagedropontheTrunk. Inpractice,atypicalIIC/GroupsA,BunitcanpoweraFieldbussegmentcomprising10Fieldbusdevices withaTrunkcablelengthofupto400m,withSpursatupto60mlength.AIIC/GroupsC,Dpower

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FISCO

supplycantypicallysupport6FieldbusdeviceswithTrunklengthsinexcessof500m.Bothexamples assumeanaveragefielddevicecurrentof17mAandtheuseoffieldbuscablewith0.8mm2cross sectionalarea,butbyusinghighercrosssections(suchas1.5mm2)withcorrespondinglowerresistance permeter,theTrunklengthcanbeincreasedsignificantly. NotethattheoutputofsomeFISCOpowersuppliesisExib,whichrestrictsthefieldwiringtoZone1 inIECapplications.SpurconvertersareavailablewherefieldinstrumentsneedtobelocatedinZone 0.IndividualSpursmaysimilarlybeadaptedtoaccommodateEntitycertifiedfieldinstruments.

Multidropcapability
SomeFISCOpowersuppliesfunctionnotonlyasaFieldbusPowerSupplyandintrinsicsafetybarrier,but alsoasaFieldbusrepeater.Normally,repeatersareassociatedwithextendingthelengthofaFieldbus segmentbyseriallyrecreatinganewsegmentendtoendwiththefirstone.Analternativeuseisto createparallelsegmentsbymultidroppinganumberofFISCOpowersuppliesfromthesameDCSH1 connection,therebycreatingmultiplehazardousareasegments.ThisisillustratedinFigure11.2.The techniquehasthefollowingpotentialbenefitsthathavebeenexploitedinexistingFISCOinstallations:

Inapplicationswherethenumberoffielddevicespersegmentislimitedduetointrinsicsafety constraints(suchasinIIC/GroupsA,BwheretheoutputvoltageandcurrentoftheFISCOpower supplyaremorelimited),combiningseveralsegmentscantakefulladvantageofthelogical capacityoftheDCSsystemsinterfacecard.ThisyieldshardwarecostsavingsintheDCSsystem. Forexample,iffourfielddevicesaresupportedoneachofthreemultidroppedhazardousarea Trunks,thentheDCSH1cardseestwelvedevices. ThescopeoflossisreducedintheeventoffailureofanysingleFISCOpowersupply,sinceother suppliesonthesamesegmentwillcontinuetooperate.

Figure11.2:FISCOpowerSuppliesinMultidropconfiguration

RedundantFISCOpowersupplies

ThisdiscussiononFISCOhassofarassumedthatthepowersuppliesarenotredundant.Redundant FISCOpowersupplymodulesarenowavailabletoincreasetheoverallsystemavailabilitybyeliminating singlepointsoffailure.

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Chapter12:CurrentLimitersforNonIncendive Protection
Summary:SincecurrentlimitersareusedontheSpurconnectionsfromtheDeviceCoupler,the connectedSpursandFieldbusdevicesinaDiv2orZone2areacanbeliveworkedwithoutpermitsifthe design/installationisdonecorrectly. NotonlydocurrentlimitersinDeviceCouplersprotectasegmentfromashortcircuitonaSpur,they alsopermitaFieldbusdevicetobeconnectedordisconnectedfromasegmentinahazardousarea withoutturningoffthepowertothesegmentorhavingtodeterminebysniffingiftheareaissafe. ThisisonlyapplicabletoDiv2orZone2areasandonlyinplacesthatallowliveworking(notinCanada, forexample).Inaddition,sincetheFieldbusPowerSupply,DeviceCoupler,SpurCables,andFieldbus DevicescanallaffectwhethertheSpurissafetolivework,eachonehasspecificrequirements: 1. TheFieldbusPowerSupplysonlyrequirementistolimitthevoltagetotheTrunk.Itmusthave acertifiedmaximumoutputvoltage.IftheSpursaretobeExic(IntrinsicsafetyforZone2), thensomethingupstreamoftheSpurmustlimitthevoltageaccordingtoIEC6007911.This couldbetheFieldbusPowerSupply,DeviceCoupler,orsomeotherapparatus.Suppliersofthis equipmentwillbeabletoprovidethenecessaryinformation. 2. TheDeviceCouplermustbecertifiedforthistypeofprotectionandhaveoutputparametersto ensuresafety.ThecurrentlimiterintheDeviceCouplerislimitingthecurrenttoasafelevel. Typically,somethingupstreamoftheDeviceCouplerislimitingthevoltage.Thenet combinationlimitsthepowerand,hence,theenergytomaketheSpurssafetolivework. 3. Spurcablesaretobelessthan120m(60mforFISCOic).Thislimitsthecapacitanceand inductancetoalevelthatisnotaconcernforsafety.Thisinformationwillstillneedtobe documentedtoshowthatthesystemissafe. 4. Finally,theFieldbusdevicesmustalsobecertifiedwithentityparametersorasaFISCOdevice forExicinstallations.AnimportantthingnottooverlookisthattheFieldbusdevicemust havetheseentityparameterswithamaximuminputvoltagethatisnotexceededbythe FieldbusPowerSupply(unlesssomeothercertifieddevicebetweentheFieldbusPowerSupply andtheSpurisfurtherlimitingthevoltage). Note:DeviceCouplersmaynotbeconnectedtoordisconnectedfromtheTrunkcablewithout determiningthattheareaissafeorwithoutturningoffthepowertothesegment. FormoreindepthcoverageofNonincendive,pleaseseethedocument502145,Nonincendive FieldbusforSimplifiedMaintenanceontheRelcomInc.website:www.relcominc.com.

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Chapter13:Grounding/Earthing
Summary:Theshield(orscreen)wireontheFieldbuscableshouldbegrounded(earthed)inoneplace typicallyneartheFieldbusPowerConditioner(whichisusuallyneartheDCS). TheFieldbusstandardisveryclearthatthetwistedpairmustNOTbegrounded.Fieldbusisintendedto beisolatedfromgroundtoimprovenoiseimmunity. Theshield(orscreen)wiremustbegrounded.WerecommendgroundingtheshieldatONLYONE POINT,andthatthatpointshouldbeneartheDCSorFieldbusPowerSupply.Careshouldbetakento preventintentionaloraccidentalgroundingoftheshieldatanyotherlocation.Acommonmistakeisto leavetheshieldexposedintheFieldbusdevice.Thiscancauseanintermittentground,resultingin intermittentcommunicationerrorswhichareveryhardtotrace.Makesurethattheshieldwiresarecut andtapedoffintheFieldbusdevices. Therearethosewhoadvocateothermethodsofgrounding.Bothoftheothermethodsinvolve groundingtheshieldinmultiplelocationseitherdirectlyorcapacitively.Thisisnotsomethingwe recommend.Formoreinformation,seetheFoundationFieldbusdocumentAG181,System EngineeringGuidelines,foradetaileddiscussionofearthingandgrounding.AG181isavailableasa freedownloadfromtheFieldbusFoundationwebsite,www.fieldbus.org.

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Chapter14:PreventingFieldbusPhysicalLayer Problems
Fieldbusishighlyreliablewhencorrectlyinstalledandmaintained.Thekeyisinknowingwhatmustbe donetostartwith,andtomaintainareliableFieldbussegment. Thepurposeofthischapteristo: IdentifycommonFieldbusphysicallayerproblems Discussthecausesoftheproblems PresentmethodsforpreventingFieldbusphysicallayerproblems ForhelpwithdiagnosingproblemswithaFoundationFieldbussegment,seetheFieldbusPhysicalLayer TroubleshootingGuide,availableatwww.relcominc.com.

CommonPhysicalLayerProblems
RelcomhavevisitedandhelpedtotroubleshootFieldbusphysicallayerproblemsformanyyears.Some problemsclearlystandout.Themostcommonproblemsinclude: MissingorextraTerminators Impropergroundingofthecableshield Water/condensationincables,junctionboxes,devices,splices,etc. NonisolatedFieldbussegments Connectorsnotsecurelypluggedin Damagedcableorwires Straywirestrandsatwireterminations Screwterminalsandholddownscrewsinadequatelytighteneddown

CausesofPhysicalLayerProblems
AfteranalyzingthelistofcommonFieldbusphysicallayerproblems,itiseasytoblameinstallersand MotherNature.However,therootcausesaredeeperthanthat: Inadequatetraining Inadequatesupervision Inadequatetools Inadequatemonitoring

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PreventingPhysicalLayerProblems
Theseproblemscanbedrasticallyreduced.Thestepstominimizetheseproblemsseemexpensiveat firstglance;however,troubleshootingjustonephysicallayerproblemcantakedaysorweeks,resulting inlargeamountsofovertime,plantdowntime,ruinedproduct,andlostsales.Fieldbusinstallations thatarecorrectfromthestartsavemoney.MonitoringthehealthoftheFieldbussegmentsandproper maintenancetechniquessaveevenmore.

Training
Trainingisnotjustcritical,itisessential.Propertrainingpriortoinstallationisthefoundationfora Fieldbusthatistroublefreeforyears. StartwiththeengineersdesigningtheFieldbus.TraintheFieldbussegmentdesignersonproper segmentarchitectureanddesign,includinghowmanyTerminatorsareinstalledoneachsegment, wheretheTerminatorsareinstalled,howlongtheFieldbussegmentandSpurscanbe,theneedfor isolatedFieldbusPowerSupplies,andpropershieldgrounding. Installersandsupervisorsmustknowhowtousethetoolsnecessaryforinstallation,wheretoroute cables,howtomountDeviceCouplers,andhowtoproperlyterminatecables(attheFieldbusPower Supply,DeviceCouplers,anddevices). Supervisorsmustbeinstructedonhowtoinspectthecablingandconnections.Theymustknowhowto identifycommonphysicallayerproblems.

Supervision
Supervisionstartsinthedesignstage.ConductareviewoftheFieldbussegmentdesignby knowledgeablepeople.Thesepeoplemaybecoworkersoranoutsidecontractor. Beforesegmentinstallationstarts,supervisorsmustensurethatpeopleworkingontheprojectare properlytrainedandhavetherighttoolstodothejob. PeoplewhosuperviseFieldbusinstallationsmusteitherinspecttheinstallationthemselvesorensure thatathoroughinspectionismadebyaknowledgeableperson.Theinspectormustbeproperlytrained, asmentionedabove,andwalkthecablerunstocheckforproblems.Theymustpullonwiresandcables toverifytheyaretight,lookfordamagedcablingandconnectors,confirmtheshieldisproperly grounded,andverifyLEDsareappropriatelylitontheDeviceCouplersandFieldbusPowerSupply. Followinginstallation,supervisorsshouldestablishaprogramtomonitortheFieldbussegmentsand makesurethemonitoringiscarriedout.

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Monitoring
OneofthestrengthsofFieldbusisthediagnosticcapabilityavailabletohelpidentifyanddiagnose problems.Inmanycases,identifyingearlysymptomscanpreventplantdowntime.Thatiswhyregular monitoringispartoftheroutineatplantsthatwanttomaximizeprofitability. SomeFieldbusPowerSupplies,suchastheF800seriesofpowersuppliesfromMTL/Relcom,provide pluginFieldbusphysicallayerdiagnosticmodules.TheF809FdiagnosticmoduleplugsintotheFieldbus PowerSupplycarrierandconstantlymonitorsthesegmentsconnectedtothepowersupply.Alarmscan besetuptoactivatewhenthemodulediscoversameasurementthatisoutofthedesiredrange.The F809Fmeasurementscanbereviewedtoidentifythecauseofthealarmsothatitcanbecorrected. Anotherapproachistouseportablediagnosticequipment,suchastheFBT6FieldbusMonitor,to measurecriticalsegmentparameters.Asetofdataiscollectedwhenthesegmentisoperatingcorrectly asabaselinereport.ThereportistransferredtoaPCforstorageorprinting.TheFBT6canbeused every6monthsorsotogenerateanotherreporttocomparewiththebaselinereportandlookfor changesthatindicateapotentialissue.Ifaproblemissuspected,theFBT6canbeusedasa troubleshootingtooltohelpisolateandeliminatethecause.

Tools
Wheninstallersandmaintenancepersonneldonothavethepropertoolstodoajob,theyoftencome upwithcreativewaystogetitdone.However,makeshifttoolsandmethodsoftenresultinproblems later. ManytoolsareavailabletohelpdeterminethehealthofaFieldbussegmentandensureproper installation.Hereisalistofthemoreimportantones.

DigitalMultimeter(DMM)
AgoodDMMcantakeresistance,voltage,andcurrentmeasurements. Measurementsofbusvoltageandshieldresistancetoground(continuity) canbetakenanytime.Resistancebetweenwiresandshieldcanonlybe measuredwhenthesegmentiswithoutpower,suchaswhenthesegment isinitiallysetuporwhendownformaintenance.

WireStripper
Goodwirestrippershelpavoidcuttingstrandsinwirefora stronger,morereliableconnection.Theyalsohelpavoid excessivewirestrippingbycuttingtoafixedlength.Thisreduces thepossibilityofshortsandwirecorrosion. Doc.No.:501123Rev.:E.0 33

PreventingFieldbusPhysicalLayerProblems

FerrulesandCrimper
Ferrulesaremetalsheathswithaplasticprotectorthatare squeezedontostrippedwireswithacrimpingtool.Ferrulesforma reliableelectricalconnection.Theyprotectwiresbyreducing breakageduetovibration,bending,andstress.Theyalsoprevent straywirestrandswhichcausecableshorts.

TorqueScrewdriver
Tomakesurescrewterminalsareadequately tightened,useatorquescrewdriver.The amountofforcethatshouldbeappliedtothe screwterminalssurprisesmostpeople. Withoutatorquescrewdriver(TheWiha TorqueFix28503screwdriverandreplaceable285373.0mmslottedbladeisanexample),screw terminalsaremostoftenundertorqued.Relcomproductsusescrewterminalsthatshouldbetightened to5inchpounds(in/lbs)oftorque.Torquescrewdriversareexpensive(~$85USD),butmuchcheaper thanplantdowntime.

FBT6FieldbusMonitor
TheFBT6isahandheldtoolthatmeasuresbusvoltage,noise, andthenumberofdevicesonthesegment,andindicateswhen devicesareaddedorremovedfromasegment.Thenoise measurementissplitinto3bands:theFieldbusfrequencyband, belowthat,andaboveit.Inaddition,itcountsretransmissionsto devices,checksforthepresenceofshieldshortstothe(+)or() Fieldbuswire,specifiestheaddressandsignallevelofeach device,andidentifieswhichdeviceistheLinkActiveScheduler (DCS).Thedatacollectedfromasegmentcanbesavedin memoryandthendownloadedtoaPCviaaUSBport.

FBT5FieldbusWiringValidator
FieldbuswiringcanbetestedusingtheFBT5WiringValidator.ItputsaDCvoltageandFieldbussignals onthewirepair.AFieldbusMonitor,theFBT6,isusedtotestthevoltage,signallevels,andnoiseon thewiring.Thesetestscanbeperformedonexistinginstrumentationwiring,newlyinstalledFieldbus cable,oraFieldbuswiringsystemwithDeviceCouplersandTerminatorsalreadyinstalled.TheFBT5is notforuseonoperatingsegmentsandcannotpowerasegmentwithFieldbusdevices.

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PreventingFieldbusPhysicalLayerProblems

Examples
ThissectionprovidespicturesofcommonFieldbus problemsencounteredinthefield. Thispictureillustrates3problems. 1. Thecableexitingtheglandatthetopofthe deviceisexceedingitsbendradius. 2. Thecableexitingtheglandatthetopofthe deviceispointedstraightuptowardthesky. Eventually,waterwillgetin. 3. Thecableglandatthebottomofthedevicehas bothacableandagroundwireexitingfromit. Cableglandswillnotformapropersealwith morethanonecablegoingthroughthem. Thecablejackethasbeenstrippedandtheindividual wiresputthroughthecablegland.Waterislikelyto enterboththecableandthedevice. WateringressintoaFieldbusdevicehas corrodedthewiresandcontacts,likelycausing thewiringtoshortoutorthedevicetofail.

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PreventingFieldbusPhysicalLayerProblems

Thisisaverynicelookingwiring stripinstallation.Cablesare labeledandcolorcoded.The terminalsarenumbered. However,thewireswerenot properlycrimpedintothe ferrulesandtheyeasilypulled out.

PreventingPhysicalLayerProblems
PreventionisthekeytoareliableFieldbussegment(i.e.,propertraining,tools,andsupervisionduring installationandmaintenance).Usequalitycableandcertifiedproductsfromreputablecompanies.Save asetofdataasabaselinewhentheFieldbusisoperatingproperly(usinganFBT6forexample). Performregularsegmentchecks,comparingcurrentdatawithbaselinedatatolookforsignificant changes.Whenproblemsareencountered,takeanewsetofdataandcompareittothebaseline.

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Glossary
Term
Attenuation Barrier

Definition
Asignalgettingsmallerasittravelsonthecable. Adeviceforinterconnectingcircuitsbetweenasafeareaandahazardous areathatpreventselectricalpowerfromthesafeareafromcausingan ignitioninthehazardousarea. Thetimedurationforonedigitalbitinthesignal. Signalwires(oneormoretwistedpairs),shield,andcoveringjacket.Each twistedpairshouldhaveitsownshield. AcommondistributionpointformultipleSpurcables,usuallyinajunction box. AcapabilityofFoundationFieldbusthatallowsthefielddevicesto controltheprocesswithouttheHost(DCS)beingdirectlyinvolved. AwiringblockforFieldbusthatincludesshortcircuitprotectionforthe connectedSpurs. Acomputerbasedcontrollerusedtocontrolaprocess. Forthepurposesofthisguide,Fieldbusisdefinedasthephysicalpartofa FoundationFieldbusorProfibusPAsegment. AnacronymforFieldbusIntrinsicallySafeCOncept.Itisasetofrules (empiricallyderivedthroughtesting)thatexpandsthecapabilitiesofa FieldbussegmentbeyondthenormalIntrinsicallySafestandards. Anopen,interoperableFieldbusstandardfordigitalcommunicationand controlofaprocess.

BitCell Cable(Fieldbus)

Chickenfoot

Controlinthefield(CIF)

DeviceCoupler

DistributedControlSystem(DCS) Fieldbus

FISCO

FoundationFieldbus

H1

ThehardwaredesignationforFieldbusat31.25kHz.Alsoincludesbitlevel communication(wrapper),butexcludesthedatacontainedinthe transmittedpackets. A1.2kHzdigitalcommunicationprotocolthatissuperimposedoverthe 420mAanalogsignalofatransmitter,valve,etc. Aplacewherevolatilevaporsorgasesmayexistsuchthattheycould igniteorexplode.

HART

HazardousArea

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Glossary

HighEnergyTrunk TheconceptofanincendivelevelofpoweronaTrunkcableandanon incendive(orIntrinsicallySafe)levelontheSpursofaDeviceCoupleror FieldbusBarrier. Themaincablebetweenthecontrolroomandajunctionboxinthefield. AlsocalledTrunk. Thedevice,usuallyinthecontrolroom,thatcontrolsormonitorsthe Fieldbussegment. AdevicethattellsotherdevicesonaFoundationFieldbussegment whentheyareallowedtotransmit. Acollectionofdevices,wiredtogetherinalimitedgeography,whichcan communicatewitheachother. Forthepurposesofthisguide,agroupofFieldbussegmentsconnected togetherinsomeway. Adeviceorcablethatwillnotcauseanignitionundernormaloperating conditionswheninthepresenceofhazardousgases.Mayormaynotbe energylimited;ifnot,disturbingthedeviceorwiringisnotallowed withoutprecautions. Adeviceorcablethatwillnotcauseanignitionundernormaloperating conditionswheninthepresenceofhazardousgases.Inthiscase,the energyislimitedandmaybeworkedwhilelive(whereallowedbylocal codes). ThefilterbetweenapowersupplyandFieldbuswiring.Normally,itispart ofaFieldbusPowerSupply. AFieldbusthatconnectstoahigherlevelProfibusNetwork(ProfiNet, ProfibusDP,etc.).Itsprotocolisdifferentandmorelimitedthan FoundationFieldbus. AFieldbusinfrastructurewhichconsistsofaFieldbusPowerSupply,two Terminators,cable,Fieldbusdevices,andaDCSH1interface. AcablebetweentheTrunkcableandaFieldbusdevice,usuallyconnected totheTrunkviaaDeviceCoupler. Adeviceonasegmentthatshapesthetransmittedsignalsandprevents signaldistortion. Themaincablebetweenthecontrolroomandajunctionboxinthefield. AlsocalledHomeRun.Usuallythecablebetweenthetworequired Terminators. Twowirestwistedtogetherfornoisecancellationpurposes,usually withinacablejacket.

HomeRun

Host

LinkActiveScheduler(LAS)

LocalAreaNetwork(LAN)

Network

NonIncendive

NonIncendiveFieldWiring

PowerConditioner

ProfibusPA

Segment

Spur

Terminator

TrunkCable

TwistedPair

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References
Thereareawiderangeofadditionalresourcesavailabletohelpyouincreaseyourknowledgeabout Fieldbus.Belowareanumberofreferencedocumentsandwebsiteswheremoreinformationcanbe found.Allreferenceswereaccurateatthetimeofprintingofthisdocumentand,alongwithallURL addresses,aresubjecttochange;however,asearchbydocumentnameandtitleislikelytofindthe mostcurrentversionofthereference.

ReferenceDocuments
FieldbusFoundation
ThedocumentsbelowareaccessiblefromtheFieldbusFoundationwebsiteat http://www.fieldbus.org/index.php?option=com_content&task=view&id=150&Itemid=326 AG140 WiringandInstallation,31.25kbits/sVoltageModeWireMedium AG163 31.25kbit/sIntrinsicallySafeSystems AG181 SystemEngineeringGuide AnotherexcellentresourcefromtheFieldbusFoundationistheFieldbusForum,forwhichyouneedto createafreeaccount.TheForumcanbeaccessedathttp://forums.fieldbus.org/.Itisavenuewhere presentationsarepostedandasearchableopendiscussionforumwherequestionsandanswerscanbe found.

RelcomInc.
ThedocumentsbelowareaccessiblefromtheRelcomIncwebsiteat http://www.relcominc.com/fieldbus/fbapnotes.htm. 500988 HighSystemAvailabilityforFoundationFieldbus 500989 TheImportanceofIsolationforFoundationFieldbus 501380 FieldbusPhysicalLayerTroubleshootingGuide 501386 PreventingFieldbusPhysicalLayerProblems 501375 TestingFieldbusCablewithFBT6andFBT5 502145 NonIncendiveFieldbusforSimplifiedMaintenance

MTL
Thefollowingapplicationnotesareavailablebyvisitingwww.mtlfieldbus.com. MTLApplicationNoteAN9026FISCOIntrinsicallySafeFieldbusSystems MTLApplicationNoteAN9027FNICONonIncendiveFieldbusSystems MTLApplicationNoteTAN1010Lightning&SurgeProtectionforFieldbusSystems

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References

ISABooks
ISAhaspublishedtworeferencebooksrelatedtoFoundationFieldbustechnology. FoundationFieldbus,3rdEdition,byIanVerhappenandAugustoPereira,providesapracticalguideto thevariousaspectsofaFoundationFieldbusproject/system.Thisbookcanbeaccessedfrom: http://www.isa.org/Template.cfm?Section=Books3&template=/Ecommerce/ProductDisplay.cfm&Produ ctID=10041 Asecond,moreindepthbook,FieldbusesforProcessControl:Engineering,Operation,and MaintenancebyJonasBerge,canbefoundat: http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm& ProductID=7563

CertifiedFoundationFieldbusTrainingCenters
ForthosewhorequireamoreindepthknowledgeofFoundationFieldbus,thereareanumberof trainingcentersinvariouspartsoftheworldthathavebeencertifiedbytheFieldbusFoundation. completionofacertifiedtrainingcoursemeansyouhavemetaminimumrequirementthatisverified againstaFieldbusFoundationstandard. LeeCollege,Texas,USA:http://knowthebus.org/fc/index.html SAIT,Alberta,Canada:http://www.saittraining.com/programs.html STCBrielle,Netherlands:http://www.stcgroup.nl TrineUniversity,Indiana,USA:http://www.trine.edu/

Websites
AnumberofusefulwebsitesexistwithinformationonFoundationFieldbus,includingthefollowing: ICEweb:http://www.iceweb.com.au/Instrument/fieldbus.htm Romilly'sHARTandFieldbusWebSite:http://www.romilly.co.uk/ FieldbusReferenceList(RonHulsebos):http://www.enodenetworks.com/Links.htm

TrainingCD
FoundationFieldbusConcepts DanDumdie HightechMultimediaTutorials POBox1927 PortAngeles,WA98362 +1(360)9289549 www.hmtutorials.com 40Doc.No.:501123Rev.:E.0

AppendixA:Signals
Thetwistedpaircables,Terminators,andtheFieldbusPowerSupplyworktogetherasawiringsystem thatcancarrysignalsbetweenFieldbusdevices. Whennottransmitting,adevicedrawspowerfromthecableforitsinternaloperation.Whenthedevice transmitsahighsignal,itdraws10mAlesscurrent.Thisincreasesthevoltagebetweenthewires. Whenthedevicetransmitsalowsignal,itdrawsanextra10mAfromthewires,resultinginavoltage decrease.Thesignalwaveformisshownbelow.Notethatthesignalisaboveandbelowthe24volt nontransmittinglevelonthesegment.

FigureA.1:FieldbusSignal

DigitaldataissentontheFieldbusatarateof31.25Kbits/second.Thus,eachbitcellis32microseconds long.ThedigitaldataonesandzerosisrepresentedasaManchestercode.Azeroisapositivesignal transitioninthemiddleofabitcell;aoneisanegativetransitioninthemiddleofabitcell. Thesignalvoltagechangeistypically750mVpeaktopeak.BecauseitisaManchesterencodedsignal, thetransition,ratherthanthemagnitude,ofthesignalisusedforcommunication.Signallevelsaslow as150mVandashighas1000mVareallowedbythestandard. AsequenceofManchesterencodedonesandzeroswouldlooklikethis:

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AppendixA:Signals

FigureA.2:ManchesterCodeSignal

Whenadevicebeginstransmitting,itputsoutatleastonepreamble,an8bitsequencewithalternating onesandzeros.

FigureA.3:Preamble

Thispatternisusedbyreceivingdevicesforsynchronizationtobitcellboundaries. Besidesonesandzeros,therearealsotwonondatasymbols.ThesenondatasymbolsareN+,ahigh levelduringthewholebitcell,andN,alowlevelduringthewholebitcell.Thesesymbolsareusedto makean8bitstartdelimiterthatshowswhererealdatastartsandan8bitenddelimiterthatshows wheredatatransmissionstops.

FigureA.4:StartandEndDelimiters

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AppendixA:Signals

Whenadevicetransmits,thedifferentpartsarecombinedtoformadataframe:

FigureA.5:FieldbusFrame

TheDataportionoftheframecontainsinformationsuchastheaddressofthedeviceforwhichthe frameisintended,identificationofthetypeofframe,measurementvalues,etc.TheDataportionofa framecanbeupto266byteslong. ThedelimitersareverydifferentfromanysignalpatternthatmightbeintheDataportionoftheframe. ThisdifferenceallowstheDataportionoftheframetobeunambiguouslyidentifiedandallowsData corruptedbynoisetobedetectedusingaFrameCheckSequence(FCS).TheFCSistheverylastpartof theDataportionoftheframe.ThisfeaturemakesFieldbusmuchmorerobustthanmanyothercontrol networks. Becausealldevicessharethecable,onlyonedeviceshouldtransmitatanygiventime.Otherwise,there wouldbechaosonthecable,withallthetransmittedsignalsinterferingwithoneanother. ForFoundationFieldbus,aspecialdevicecalledtheLinkActiveScheduler(LAS)selectswhichsingle devicecantransmit.TheLASallowseachdevicetotransmitbysendingoutaspecialframetoeach deviceinturn.AframemightbetheLASaskingadevicetotransmitdata,adevicebroadcastingitsdata tootherdevices,adevicereportinganerrorcondition,etc. ProfibusPAusesamaster/slavearchitectureratherthananLAS.Themastercontrolswheneachdevice onthesegmenttransmits.

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AppendixB:AvailabilityCalculation
ThefollowingisbackgroundinformationonhowtheAvailabilitywasdeterminedfortheexampleon page18. Tocalculateavailability,wealsoneedtoknowtheMeanTimeToRepair(MTTR).TheMTTRforafailure whichraisesanalarmistypicallytakenas8hours(1shift)tocoverthetimetakentorecognizethe alarm,getthenecessaryauthorizationstoworkonthesystem,collectasparefromstores,and completethereplacement. TheAvailabilityis TocalculatetheavailabilityoftheFieldbussegmentduetothepowersupply,weneedtoconsider: TheMTTFoftheisolatorandpowerconditioningmodulesand TheMTTFofthecommoncomponentsonthebackplanewhosefailurewouldresultinthe failureoftheFieldbussegment. Withtwopowersupplymodulesoperating,theUnavailability(1Availability)oftheredundantpower supplyistheprobabilityofbothmodulesbeingunavailableatthesametime.Thisiscalculatedasthe productoftheindividualpowermoduleunavailabilities. TheUnavailabilityfortheFieldbussegmentisbasedon: Boththeisolationandpowerconditioningmodulesfailingatthesametime,or Thecommonbackplanecomponentsfailingwhichaffectsegmentavailability. TheUnavailabilityoftheFieldbussegmentisthesumofthesetwounavailabilities.

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AppendixC:FieldbusSegmentDesign Calculation
Thefollowingexampleshowshowtocalculatethemaximumnumberofdevicesthatcanbeattachedat theDeviceCoupler. TheFieldbusPowerSupplyminimumoutputis22Voltstothesegment. Thecableusedis18gaugeandhasaresistanceof22Ohms/kmforeachconductor.TheTrunk cableis1kmlong.Thecombinedresistanceofbothwires(roundtrip)is44Ohms. EachdeviceattheDeviceCouplerdraws17mA. AlthoughtheminimumvoltageforaFieldbusdeviceis9V,wewantasafetymarginof2V.Thisleaves11 voltsthatcanbedroppedbythecable(2292).ThetotalcurrentthatcanbesuppliedattheDevice Coupleris: Voltage/Resistance=Currentavailable 11Volts/44Ohms=250milliamps WewanttoallowaSpurtobeshortedandstillhave11voltsattheDeviceCoupler.Wealsowanttobe abletoconnectahandheldtestertotheDeviceCoupler.Finally,thecurrentdrawoftheDeviceCoupler mustalsobetakenintoaccount.Thisleavesacurrentof175mAavailablefordevices(25060105). Sinceeachdevicedraws17milliamps,themaximumnumberofdevicesattheDeviceCouplerofthis exampleis: Currentavailable/Devicedraw=Numberofdevices 180mA/17mA=10devices BeawarethattherearemanySegmentCalculatorsavailablefrommanufacturersofFieldbusequipment, aswellasonethatisavailablefromtheFieldbusFoundation(www.fieldbus.org).

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Fieldbus
WiringGuide

Relcom Inc.

2221YewStreet ForestGrove,OR97116 (503)3575607 (800)3823765 (503)3570491(fax) www.relcominc.com